An Electric Future for Mine Haulage · Dr. Bappa Banerjee Energy and Mines World Congress December...
Transcript of An Electric Future for Mine Haulage · Dr. Bappa Banerjee Energy and Mines World Congress December...
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An Electric Future for Mine HaulageDr. Bappa BanerjeeEnergy and Mines World CongressDecember 4, 2019
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Overview• Social demands and key mining trends
- Electrification/Automation/ Connection
• Path to Electrification
- Electric Truck Roadmap
- Batteries and Energy Storage
- Charging and Trolley
• Value/Operations
- Options
- Simulations; Impacts on Fuel/Productivity
• Conclusion
Social demands and key mining trends
“Mining is not a choice – the way we mine is.”Dr. B. Banerjee
Key Trends in Mining
Automation Connection
Electrification
• Safety• Utilization• Throughput• Asset life
• Safety • System efficiency• Optimization
• Emissions• TCO• Productivity
The economic, environmental, and social benefits of sustainability
Source: A.T. Kearney analysis
Balanced Innovation Model
Viability
DesirabilityFeasibility
Ideohttps://www.ideou.com/blogs/inspiration/how-to-prototype-a-new-business
• Does this work? • Is it functionally possible in the
foreseeable future? • Will it run a shift?• Can it fit in the vehicle?• Will it work in all environments?
• Can we build a sustainable business? • What has to be true for this business to work? • What are the costs? • How will you pay for it?• Replacement frequency?• CAPEX? OPEX?• Does it lower $/ton?
• What’s the unique value proposition? • Do people want this product or service? • Does it make sense for them?• Eliminate diesel?• Flexible?• Fit the way mines operate?• Will it meet production needs?• Does it lower $/ton?
Path to Electrification
Electrification Journey
• Decouple vehicle from engine RPM• Electric Retarding…
zero wear deceleration• Gears• Bearings• Durability
Electric Drive Optimization Prime Mover Non Traction
もったいない
Electrification Journey
95%
100%
105%
90% 95% 100%
Prod
uctiv
ity v
s. B
asel
ine
Fuel Consumption vs. Baseline
Base Truck
Optimized cooling
• Parasitic cooling power matched to dynamic component needs
• Simplified ducting• Increase HP to wheels• Retard energy for
cooling
• Improved Fuel Efficiency…. $• Increased speed on grade…Tons
Electric Drive Optimization Prime Mover Non Traction
DIESEL POWERED All EV POWEREDHYBRID POWERED
Benefits:• ↓ emissions• ↓ fuel• ↑ productivity• ↑ transient response
Benefits:• Zero emissions• ↓ noise• ↓ LCC• ↑ productivity
Current configuration:• 2500 HP engine• AC alternator
Configuration:• 2500 HP engine• AC alternatror• ES Boosts Performance• ~200kWh
Configuration:• Engine, alt, radiator
eliminated• 800 – 1200 kWh ES• Trolley system or roadAnd/Or• Stationary charge system
Electric Drive Optimization Prime Mover Non Traction
240t exampleElectrification Journey
Electrification Journey Electric Drive Optimization Prime Mover Non Traction
Radiator/Alt. losses
Equivalent Electric Power
Inverter & TM Cooling & Other Loads
Truck operation loads- Dump body hydraulics- Steering- Brakes- Cab A/C
Electrification
KPI element $/ton impact Hybrid Full EV
Productivity Very High + + +Availability High + +Fuel Medium + + +CAPEX Low - - -
+ -Engine: fuel, maintenance
CAPEX – Truck, Battery Life, Stationary Charger, Fleet Size
Emissions Trolley: CAPEX, Mtce, Road & Operations flexibility (Mtce, Width)
Energy Costs Battery Disposal
Noise Training
Production
Tradeoffs
Battery vehicles and integrationBattery Chemistry Evaluation
1960’s 1970’s 1980’s 1990’s 2010’s2000’s
7T LHD – 2016(prototypes)
Li-Ion POC - 2017
Edison & 1913Electric Car
Commercial Hybrids
2020’s
Battery Electric LocomotiveCARB Demo – 2020
Battery Electric Truck(initial concept phase)
GE Energy Storage Business Launch
Beta Acquisition & NaMx Dev’t
Battery Chemistry Re- Evaluation
GRC Automotive Product Development Support
Hybrid POC’s in Marine, Loco, Mining
General Electric Company GE Transportation GE Transportationa Wabtec Company
2008 DoE Hybrid Proof of Concept
Technology Demonstrator:• Demonstrate Battery Diesel Hybrid
technology• Joint Effort between GE, Komatsu and
US DoE… Primary goal – Fuel Savings• Na-NiCl2 (ZEBRA) battery technology
(~432kWh, 18000lbs/8180kg)• Komatsu Arizona Proving Grounds• Fuel Savings 3% to 5% realized
Successful Demo Jan. 2008
Komatsu 830E-1AC
Energy Storage: Trends
• “NMC” (NMC/Graphite and derivatives) energy density and cost expected to continually improve
NMCNMCNMCNMCNMCLFPLTO
LTOLFP
NMC + DerivativesCellEnergyDensity[Wh/kg]
Start of Production [year]
Trolley
1960 1970 1980 1990 2000 20101960 1970 1980 1990 2000 2010 2017
Historic Oil Prices50 trucks installed in the 00’s
System that delivers electric power to a haul truck from an overhead line.The electric power supplements power from the engine to increase speed on grade.
What is Trolley Assist
Benefits of Trolley Assist• Increase speed on grade• Decrease fuel consumption• Charge while running
• Extend diesel overhaul schedule• Reduce emissions
• First GE systems were installed at a Cement Company in the late 1950’s• Majority of systems were installed during the 1980’s in response to the energy crisis of the 1970’s • Revitalization of Interest: Trolley is a key enabler for Battery Truck.. GHG, Environmental Impacts
History
200 GE trolley assist trucks installed in the 80’s
Stationary Charging
Stemmann-Technik• Required power transfer for trucks would exceed stationary systems developed for buses• Power requirements more consistent with ferry (marine hybrid/electric ship) chargers
Stemmann-Technik
Bus Charging Ferry Charging
LV to 4MWMV to 8MW
LV to ~600kW
Value/Operations
Configurations
Base Truck
Hybrid
240t exampleAll EV + Trolley
Stationary Charger
2500 HP + 200 kWh battery
800 kWh battery only
1200 kWh battery only
2500 HP Diesel Engine
All EV + Stationary Charging
60%
70%
80%
90%
100%
110%
120%
130%
0% 20% 40% 60% 80% 100% 120%
Nor
mal
ized
Pro
duct
ivity
(ton
s/hr
)
Normalized Energy Cost ($/ton)
Baseline
Uphill FlatDownhill
2
3
41
2
3
4
1 Hybrid• Incremental fuel and productivity
improvement on Uphill and Downhill profiles
• Highest operational flexibility
Downhill Hauls• No value to trolley• EV w/Stationary – high value even with
time penalty
Uphill Hauls• Ideal EV + trolley... Flexibility impact• EV + Stationary… delivers flexibility…
look at CAPEX
Flat Hauls• Trolley creates speed penalty…little
value• EV + Stationary – best impact… look at
CAPEX
Energy Cost ($/ton) vs Productivity (ton/hr)
Conclusion
The Future is Electric
Viability
DesirabilityFeasibility
• No ‘universal’ cell• Packaging is critical
• Substantial benefits• Investments & Viability• Technology trend
• Application, Configurationand Value
• Flexibility vs. Benefit
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