How do you calculate total energy consumption for mixed electric equipment fleets?

Calculating total energy consumption for mixed electric equipment fleets requires measuring power usage across different equipment types, accounting for varying operational patterns, and understanding how factors like duty cycles and load characteristics affect overall consumption. Container terminals increasingly rely on diverse electric equipment, making accurate energy calculation important for infrastructure planning, cost management, and decarbonisation efforts. This analysis helps terminals determine charging requirements, evaluate grid capacity needs, and optimise operational strategies for battery-powered equipment.

What does mixed electric equipment fleet mean in terminal operations?

A mixed electric equipment fleet comprises different types of battery-powered or electrically driven machinery operating simultaneously within a terminal environment. This typically includes:

  • Automated stacking cranes
  • Automated guided vehicles
  • Reach stackers
  • Electric rubber-tyred gantry cranes
  • Straddle carriers
  • Terminal trucks

Each equipment type operates with distinct power requirements, duty cycles, and energy consumption patterns.

Terminals operate mixed fleets rather than uniform equipment types because operational requirements vary across different handling zones. Quay-side operations demand different equipment capabilities than yard operations or gate activities. Equipment selection depends on container throughput volumes, stacking strategies, available space, and automation levels. Some terminals transition gradually from diesel to electric equipment, creating mixed fleets during the conversion period.

Energy calculation becomes complex with diverse equipment because each type draws power differently. Automated stacking cranes consume energy continuously during operation, whilst horizontal transport equipment requires intermittent charging between moves. Battery-powered vehicles may use fast charging, opportunity charging, or battery swapping strategies, each affecting total energy demand differently. This diversity requires detailed analysis to determine accurate consumption figures across the entire fleet.

How do you measure energy consumption across different equipment types?

Measuring energy consumption across diverse terminal equipment involves combining direct monitoring systems with operational data analysis. Three primary measurement approaches provide comprehensive energy insights:

Measurement Method Application Key Considerations
Direct metering Power monitoring equipment provides real-time consumption data for individual machines or charging stations Captures actual energy usage during different operational states, including active handling, idle periods, and peak load conditions
Manufacturer specifications Baseline consumption figures for equipment under standard operating conditions Requires adjustment for actual terminal operations, as real-world consumption varies based on handling intensity, container weights, travel distances, and environmental factors
Operational data analysis Historical performance records to identify consumption patterns Examines patterns across shifts, seasons, and throughput levels to establish representative consumption figures

Different equipment types exhibit varying energy profiles that must be captured separately. Continuously operating equipment like automated stacking cranes maintains steady power draw throughout operational periods. Intermittently operating equipment such as straddle carriers or terminal trucks shows fluctuating consumption patterns tied to individual container moves. Accurate measurement requires tracking these patterns over extended periods to account for operational variability and establish representative consumption figures for capacity planning.

What factors affect total energy consumption in mixed equipment fleets?

Multiple interconnected factors influence energy consumption in terminal operations. Understanding these elements enables terminals to forecast demand accurately and identify efficiency opportunities, particularly when addressing common industry challenges related to electrification:

Operational Factors

  • Operational intensity – Higher container throughput increases equipment utilisation and power demand
  • Duty cycles – Frequency of equipment operation at full capacity versus idle or reduced power states
  • Equipment age and efficiency – Older machinery typically requires more energy for equivalent work output compared to modern, optimised designs
  • Operational patterns – Frequency of acceleration and deceleration cycles affects total consumption as these movements represent significant energy expenditure

Environmental and Load Factors

  • Environmental conditions – Temperature extremes reduce battery efficiency, requiring additional charging to maintain operational capacity
  • Load characteristics – Moving heavier containers demands more power than handling empty units
  • Seasonal variations – Trade volume fluctuations create varying energy patterns throughout the year

Compounding Effects

These factors interact in ways that compound their individual effects. Peak operational periods combine high throughput with intensive equipment usage, creating maximum energy demand. Research indicates that terminals may require an additional 10-25 per cent of fleet capacity when operating battery-powered equipment to maintain equivalent performance levels, partly due to charging time requirements. Understanding these interactions enables more accurate consumption forecasting and helps identify opportunities for operational efficiency improvements that reduce overall energy usage.

How we help with energy consumption analysis for terminal equipment

We support container terminals in calculating and optimising energy consumption for mixed electric equipment fleets through detailed simulation analysis and operational modelling. Our approach addresses the specific challenges of electrification by quantifying energy requirements under realistic operational conditions before infrastructure commitments are made.

Our services for energy consumption analysis include:

  • Simulation modelling that forecasts energy requirements by tracking active equipment per hour and moves executed across a full operational year, accounting for dynamic workload patterns and varying operational intensity
  • Charging strategy evaluation testing different battery sizes, charging approaches (fast charging, opportunity charging, battery swapping), and charger quantities to determine optimal configurations that meet energy demands without compromising terminal performance
  • Business case evaluation that incorporates energy costs, infrastructure requirements, and operational impacts into financial assessments, helping terminals understand the full cost implications of electrification decisions
  • Infrastructure dimensioning that determines charger numbers, locations, and power grid capacity requirements based on fleet size, operational patterns, and performance targets
  • Operational improvement planning that identifies efficiency gains reducing energy consumption—our evaluation of improvement studies shows energy consumption can be reduced by 12-16 per cent through operational enhancements alone

Our validated simulation models track battery status and power consumption over time as per real-life operations, enabling terminals to quantify impacts of various electrification solutions on performance and equipment productivity. This data-driven approach supports informed decision-making for port logistics consulting projects and container terminal electrification initiatives, helping terminals navigate the transition to electric equipment whilst maintaining operational efficiency.

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

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