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Fuel-Saving Solution for Forklifts Using Hydraulic Energy Storage and Regeneration Device Cluster Additionally Installed

Nguyen Van Tinh

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no 4

137--148

EN

Forklifts are indispensable vehicles in warehouse logistics work. Large forklifts have a common configuration that uses a combustion engine to create energy to drive the machine's hydraulic system. Due to the characteristics of diesel engines, a large amount of energy is wasted and harmful gases are emitted every day. Especially with millions of older-generation forklifts and construction machines being used in developing countries, the above problem is even more serious while immediately replacing them with new generation machines is impossible. To solve this, the solution is to design and manufacture an additional device cluster to save fuel and reduce emissions. It is both economically and environmentally viable with the right technology. This article proposes the structure and working principle of an additional hydraulic device cluster to increase the working efficiency of the above types of forklifts. Based on building a mathematical model of the mechanical-hydraulic system during the lowering and lifting processes when applying the solution, the main parameters of the process were surveyed. The solution applied on a 3.5 tons forklift shows that the renewable energy percentage in one lowering and lifting cycle is 65.5%. The amount of diesel saved in a year is 2057 liters, corresponding to the one of CO2, CH4 and N2O emissions removed by 5.55 tons, 223 grams and 326 grams, respectively. The proposed device cluster installation is easy with older-generation forklifts and can also be applied in the production of new forklifts.

2

Dobór materiałów do budowy kompaktowego regeneratora ciepła dla ekonomicznych palników gazowych o niskiej emisyjności CO2

Wnęk M.

Hutnik, Wiadomości Hutnicze

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2018

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Vol. 85, nr 1

21--26

PL

W okresie znaczącej konkurencji, wysokich cen energii i zmniejszania zasobów paliw kopalnych, które są niezbędne w technologiach metalurgicznych, wymaga się bezwzględnie od urządzeń cieplnych wysokiej sprawności przy jednoczesnym spełnieniu rosnących ograniczeń ekologicznych. Wykorzystywanie efektywnych metod podgrzewu powietrza jest jednym ze sposobów znaczącego obniżenia zużycia paliwa i ograniczenia emisji CO2 w cieplnych procesach metalurgicznych. Najbardziej wydajne pod względem temperatury podgrzewanego powietrza są systemy regeneracyjne, które w rozwiązaniach z indywidualnymi regeneratorami palnikowymi umożliwiają uzyskanie temperatury podgrzewu powyżej 1000ºC. Przygotowano do analizy kilka materiałów, z których wypełnienie regeneratora może być wykonane. W badaniach przydatności materiałów do budowy regeneratora uwzględniono dwie metody – symulację i badania stanowiskowe. Wstępne oszacowanie konstrukcji wypełnienia regeneratora przeprowadzono z wykorzystaniem autorskiego programu, w którym zastosowano uproszczoną teorię regeneratorów ciepła. Potwierdzona w badaniach stanowiskowych możliwość osiągnięcia przez regenerator wysokiego podgrzewu powietrza pozwala uzyskać znaczące oszczędności w zużyciu paliwa, a w konsekwencji podwyższa również sprawność pieca grzewczego, co powinno wzbudzić zainteresowanie przemysłu metalurgicznego z ekonomicznego punktu widzenia. Dodatkową korzyścią jest także zmniejszona emisja CO2, co stanowi bardzo ważny aspekt środowiskowy.

EN

In times of intense competition, high energy prices and reduced fossil fuel resources require high-efficiency heat devices while meeting the growing ecological constraints. The intensification of the heat flow and the efficiency of the furnaces are achieved primarily by increasing the temperature of the combustion air. The high preheated air combustion technology provides most effective heat recovery, reduction of energy consumption, cleaner and cheaper production. The most efficient in terms of the heated air temperature are the regeneration systems which, in solutions with individual burner regenerators, allow the heating temperature to reach 1000ºC. A few materials for the regenerator filling have been considered. The two experimental methods have been used – numerical simulation and research on the built test stand. Each regenerator construction is characterized by its own construction parameters which influence the heat transfer and thus an air preheat. Basically, only the dynamic model of the regenerator is able to indicate the appropriate results. Stationary tests have shown very good usefulness of chosen material as a regenerator filling. The high air preheat gives significant fuel saving and this shows that considered material of regenerator is quite an interesting solution. The reduction of fuel consumption increases also the furnace efficiency. It means that a lot of CO2 would not have been emitted into the environment, as well. Presented solution could be interesting for the metallurgical industry from the economic and environmental point of view.

3

Techno-economic approach to solar energy systems onboard marine vehicles

Salem A. A., Seddiek I. S.

Polish Maritime Research

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2016

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nr 3

64--71

EN

The world is facing the challenge of continuously increasing energy consumption. At the same time, the energy resources are getting scarcer. Despite a sudden significant drop of fuel prices worldwide, research activities that focus on reducing the dependence on fossil fuels as a traditional source of energy still have the preference in the field of shipping industry. The use of clean and renewable energies, such as solar energy for instance, is proposed as a method to improve the ship efficiency. Ships can get the benefits from solar energy due to the fact that most of their upper decks are always exposed to the Sun, especially in sunny water regions. The present paper discusses the effectiveness and challenges of installing solar panels for auxiliary power production on board a ship. As a case study, the research evaluates both economic and environmental benefits resulting from implementing such concept aboard a research vessel.

4

Drivers’ adaptive travel behaviors towards green transportation development: a critical review

Shafaghat A., Keyvanfer A., Muslim N. H. B.

Archives of Transport

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2016

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Vol. 38, iss. 2

49--70

EN

The transportation professionals integrated the concept Green in various dimensions of transportation, such as, green vehicle, green highway. The current study has established a new dimension to green transportation, which is called Green Driver as whom substantially contributes to less emission and fuel consumption, and higher-safety. The research established the driver’s Green Adaptive Travel Behaviors (GATB), in particular, that is referred to voluntary personal and lifestyle behaviors on less energy consumption and emission. The methodology was designed into two phases. Phase one was to investigate driver’s GATBs through systematic literature review process and content analysis method. The second phase was to verify greenery value impact (GVI) of the finalized list of drivers’ GATBs through an expert input study and Grounded Group Decision Making (GGDM) method. Total twenty six (26) GATB factors have been determined. Amongst, the factor ‘F27- Dangerous overtaking’ has received the highest value (97%) followed with ‘F3- Slow once realizing bike lanes for cyclist crossing’ (91%). In contrast, ‘F4- Realize visual Obstacles to manage the speed’ and ‘F21- Brake with smooth deceleration’ has received the lowest value (77%) among other factors. Two of the initial factors;‘F5-Use traffic calming devices’ (55%), and ‘F24- Change highest possible gear’ (69%) could not reach the 70% saturation; hence, they have been dropped from the list of GATB factors. Indeed, the GATB efforts are not limited to technology and practice; but also can include education and enforcement to driving regulations in order to interconnect driver, technology, environment, and vehicle. The research concluded with an innovative technique used as the decision support tool to evaluate the greenery grade of any individual driver on committing to less emission, less fuel consumption, and higher safety in traveling. As future study, the Green driver behaviour index assessment model will be developed based on this study outputs.

5

Adjustable speed power generation systems with diesel genset

Iwanski G, Koczara W

Silniki Spalinowe

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2009

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R. 48, SC1

141--146

EN

The paper presents diesel based power generation systems operating with variable speed. Load adaptive adjustable speed operation of diesel engine based generation systems provide significant reduction of fuel consumption and eliminate artificial dump resistive load, used for improving the fuel combustion in fixed speed generation systems during low load operation. Two power generation systems topologies dedicated for adjustable speed gensets are discussed. First system uses a power electronics converter as a coupler between synchronous generator and isolated load or power grid. The second system, attractive especially for MW range power gensets, uses doubly fed induction generator DFIG excited from the rotor connected power electronics converter. The paper describes the features of power electronics generation systems and their advantages in fuel saving on the basis on simplified mechanical characteristics of the diesel gensets. Results of operation of industrial version of variable speed integrated generation VSIG system based on 40kVA diesel genset are presented. Laboratory test results of small scale model of DFIG system are shown.

PL

W artykule opisano układy wytwarzania energii dedykowane do zespołów prądotwórczych z silnikami spalinowymi o regulowanej prędkości. Dopasowanie prędkości do aktualnego obciążenia poprawia spalanie paliwa oraz zmniejsza jego zużycie, a także eliminuje konieczność stosowania sztucznego obciążenia w przypadku pracy z niskim obciążeniem rzeczywistym. W pierwszym z przedstawionych systemów zastosowano przekształtnikowy układ energoelektroniczny sprzęgający izolowane obciążenie lub sieć z napędzanym silnikiem diesla generatorem synchronicznym. Drugi układ, dedykowany dla systemów o mocy rzędu MW, wykorzystuje prądnicę indukcyjną dwustronnie zasilaną (ang. DFIG) wzbudzaną od strony wirnika z przekształtnika energoelektronicznego. W artykule opisano właściwości energoelektronicznych układów wytwarzania energii i ich zalet w redukcji zużycia paliwa na podstawie uproszczonych charakterystyk mechanicznych silników diesla. Przedstawiono wyniki testów przemysłowej wersji zintegrowanego układu wytwarzania energii o regulowanej prędkości zbudowanego w oparciu o 40kW silnik diesla. Przedstawiono również wyniki testów laboratoryjnych układu modelowego małej mocy z prądnicą dwustronnie zasilaną.

6

Regeneracyjne palniki gazowe dla pieców grzewczych wysokotemperaturowych

Tomeczek J., Wnęk M.

Hutnik, Wiadomości Hutnicze

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2005

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Vol. 72, nr 9

461-465

PL

Zaprezentowano wyniki badań wypełnienia regeneratora typu "sunflower" dla kompaktowych palników regeneracyjnych instalowanych w wysokotemperaturowych piecach grzewczych. Wypełnienie będące regeneracyjnym podgrzewaczem powietrza oraz stanowiące system dysz powietrznych o odpowiedniej konstrukcji umożliwia uzyskiwanie wysokich temperatur podgrzewanego powietrza powyżej 1000 °C. Zintegrowanie tego regeneratora z palnikiem GAFT (Gas-dynamic abated flame temperature), pomimo wysokiego podgrzewania powietrza, może zapewnić emisję NO, poniżej dopuszczalnych norm.

EN

The experimental results of a regenerator filling called " sunflower" for the compact regenerative burners are presented. This regenerator filling playing also the role of nozzle system is able to reach a very high air preheat. The air temperature as high as 1000 °C has been achieved. Integration of the GAFT (Gas-dynamic abated flame temperature) burner with the SUNFLOWER regenerator should enable to obtain a very low NOX emission.

7

Theoretical and experimental study of the automotive fuel saving

Copae I., Chereches T.

Zeszyty Naukowe Politechniki Rzeszowskiej. Mechanika

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2004

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z. 62 [209]

49--54

EN

The paper presents some theoretical considerations concerning the energetic efficiency and fuel saving of the machines, as a general issue, and of the automotive as a specific issue. The paper also presents experimental aspects with respect to the vehicle's fuel consumption. The main assessment indices of the vehicle's and engine's fuel saving are stressed. Theoretical and experimental results, according to some test data are provided. The work also makes some connections to the fuel usage efficiency and the components of the energetic balance are presented. The work makes a comparison between the fuel consumplion and the degree of the energy usage for different working conditions of the vehicles that have electronically controlled engines and mechanical transmissions.