How do ultracapacitor systems complement battery technology in terminal equipment?

Ultracapacitor systems complement battery technology in terminal equipment by managing high-power demands and capturing regenerative energy during braking, whilst batteries provide sustained energy for continuous operations. This hybrid approach extends battery lifespan, reduces maintenance requirements, and improves overall equipment efficiency. Container terminal electrification increasingly relies on these complementary energy storage systems to address the operational demands of rubber-tyred gantries, straddle carriers, and automated guided vehicles.

What are ultracapacitors and how do they differ from batteries in terminal equipment?

Ultracapacitors, also known as supercapacitors, store electrical energy in an electric field rather than through chemical reactions like batteries. They charge and discharge extremely rapidly, deliver high power output for short durations, and tolerate hundreds of thousands of charge cycles compared to several thousand for batteries. Ultracapacitors perform consistently across wider temperature ranges and experience minimal degradation over time.

These operational differences matter significantly for terminal equipment operations. Rubber-tyred gantries require substantial power bursts when lifting containers, whilst straddle carriers need rapid acceleration and deceleration during horizontal transport. Automated guided vehicles operating in port logistics environments face similar demands with frequent stop-start patterns throughout their duty cycles.

Batteries excel at storing large amounts of energy for sustained operations but struggle with rapid charge acceptance and high-power discharge events. When equipment accelerates quickly or lifts heavy loads, batteries experience stress that shortens their operational life. Conversely, ultracapacitors handle these power spikes efficiently but cannot store sufficient energy for extended operations. Terminal equipment requires both capabilities, which explains why hybrid systems combining these technologies have become increasingly relevant for container terminal electrification projects.

Key differences between ultracapacitors and batteries

Characteristic	Ultracapacitors	Batteries
Energy storage method	Electric field	Chemical reactions
Charge/discharge speed	Extremely rapid	Moderate
Power delivery	High power, short duration	Sustained power, longer duration
Cycle life	Hundreds of thousands	Several thousand
Temperature tolerance	Wide range	Limited range
Degradation over time	Minimal	Moderate to significant

How do ultracapacitors and batteries work together in hybrid terminal equipment systems?

Hybrid energy storage systems use ultracapacitors for peak power demands whilst batteries provide baseline energy for continuous operations. The power management system monitors operational requirements and directs energy flow between the two storage technologies based on instantaneous power needs. During acceleration and container lifting, ultracapacitors deliver the high-power output required, protecting batteries from damaging discharge rates.

When equipment decelerates or lowers containers, the system captures regenerative energy. Ultracapacitors accept this energy rapidly, storing it for the next acceleration or lifting cycle. This regenerative capture would otherwise be lost as heat or would stress batteries beyond acceptable charging rates. The battery system supplements the ultracapacitors during sustained operations, recharging them between power events whilst maintaining equipment operation.

Straddle carrier handling cycle example

Operation phase	Primary energy source	Function
Acceleration from standby	Ultracapacitors	Provide immediate high power
Travel to container stack	Batteries	Maintain steady speed and recharge ultracapacitors
Container lifting	Ultracapacitors	Supply peak power demand
Transit with container	Batteries	Handle sustained load
Lowering and deceleration	Ultracapacitors	Capture regenerative braking energy

This division of labour optimises each technology’s strengths whilst minimising their respective limitations.

What benefits do ultracapacitor-battery hybrid systems bring to terminal operations?

Hybrid systems extend battery lifespan substantially by reducing stress from high-power events and rapid charging. Batteries in hybrid configurations experience fewer deep discharge cycles and lower peak currents, which directly translates to extended operational life. This reduces replacement frequency and associated downtime for battery changes, improving equipment availability.

Energy efficiency improves through effective regenerative energy capture. Research on terminal electrification shows that battery-only systems struggle to accept regenerative energy quickly enough, wasting potential energy recovery. Ultracapacitors capture this energy efficiently, reducing overall energy consumption from the grid. This matters particularly for terminals where equipment operates continuously with frequent acceleration and deceleration patterns.

Key operational benefits

Extended battery lifespan – Reduced stress from high-power events and fewer deep discharge cycles significantly increase battery operational life
Improved energy efficiency – Effective regenerative energy capture reduces overall grid consumption by up to 30% in high-cycle operations
Reduced maintenance costs – Slower battery degradation and minimal ultracapacitor maintenance requirements lower ongoing operational expenses
Consistent performance – Equipment maintains power delivery capabilities throughout operational life with minimal degradation
Increased equipment availability – Less frequent battery replacements mean reduced downtime for maintenance activities
Enhanced operational flexibility – Better handling of variable duty cycles and unpredictable operational demands

The total cost of ownership calculation shifts favourably despite higher initial equipment costs. Whilst hybrid systems cost more initially, reduced battery replacement frequency, lower energy consumption, and improved equipment availability offset this investment. Terminals considering electrification must account for these long-term operational benefits when comparing battery-only systems to hybrid configurations. Different equipment types and operational patterns affect these calculations, with equipment experiencing frequent power transients benefiting most from hybrid systems.

How we help terminals evaluate hybrid energy storage solutions

We approach hybrid energy storage assessment through detailed simulation analysis that models your specific operational patterns and equipment requirements. Our methodology examines how different energy storage configurations perform under your terminal’s unique conditions, providing evidence-based insights for technology investment decisions.

Our evaluation process includes:

Analysis of equipment duty cycles and power profiles – We examine your equipment’s actual operational patterns, identifying peak power events, regenerative opportunities, and sustained energy requirements throughout typical working shifts
Financial modelling of hybrid versus battery-only systems – We compare total cost of ownership across different configurations, accounting for equipment costs, energy consumption, maintenance requirements, and replacement cycles
Simulation of energy consumption patterns – Using validated simulation models, we test energy usage over full annual operations, capturing seasonal variations and operational peaks that affect system performance
Evaluation of different hybrid system configurations – We assess various ultracapacitor and battery sizing combinations to identify optimal configurations for your operational requirements and budget constraints
Assessment of infrastructure requirements – We determine charging infrastructure needs, including charger quantities, locations, and grid connection requirements that hybrid systems demand
Integration planning with existing or planned automation systems – We examine how hybrid energy storage integrates with your current operations or planned automation implementations, ensuring compatibility and optimal performance

Deliverables from our analysis

Analysis component	Outcomes
Equipment performance modelling	Quantified impacts on terminal throughput and productivity
Energy consumption analysis	Projected annual energy costs and savings potential
Fleet sizing recommendations	Optimised equipment quantities for operational requirements
Financial comparison	Total cost of ownership across different technology options
Infrastructure planning	Charging station requirements and grid connection specifications
Implementation roadmap	Phased deployment strategy minimising operational disruption

This simulation-based approach allows you to test different scenarios without committing to specific technologies or disrupting existing operations. Our analysis quantifies the impacts of various energy storage solutions on terminal performance and equipment productivity, helping you determine fleet size requirements, battery specifications, and charging strategies that meet your operational needs. The outcomes inform business case assessments and support informed decision-making about energy storage technology investments for your terminal’s specific circumstances. To learn more about our approach to addressing these and other industry challenges, or to explore our comprehensive range of services for container terminal optimization, please visit Portwise Consultancy.

If you’re interested in learning more, reach out to our team of experts today.

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