Mobile Mining: Trucks, Trolley, Shovels Minerals Day Chile … · Mobile Mining: Trucks, Trolley,...

Minerals Day Chile – 2015Innovative Drives for Trucks and Shovels

Mobile Mining: Trucks, Trolley, Shovels

Agenda

• Overview of Mobile Mining

• Shovel Portfolio

• Truck Portfolio

• Truck Trolley System

• Software Options

• Summary

Safety is our top priority

Safety

Reliability

Productivity

Trends of the Mining Industry

To achieve best results, the mining industry is producing

bigger machines, capable of higher payloads

faster speeds

smarter & autonomous operation capability

Leading to • Increased productivity, increased reliability and reduced

operating costs.

Mobile Mining Global Center of CompetenceAlpharetta, GA – USA

Mobile Mining Portfolio

Integrated electrical / mechanical drive systems, augmented with innovative software / technology features and services for Trucks, Shovels and Draglines

Electric Drives and Drive Trains for Mobile Mining Equipments

Derived from locomotive traction systems, mobile mining motors and inverters offer a reliable high-power drive system, suitable for the rough environmental conditions of surface mining.

Integrated drive train – Gearbox matched with motor and inverter to allow toughest duty cycles for trucks and achieve high gradability

Customer value

High reliabilityProven train technology for extreme environmental conditionsHigh mean time between failure (mtbf) and low mean time to repair (mttr) for high availabilityGlobal service network for quick responseLow Lifecycle Cost (LCC)

Electric Rope Shovels & Draglines

1976 Analog SCR AC Shovel drives

1983 680W modular walking Dragline with all motions AC Drives

1989 Digital GTO AC Shovel drives

1999 Introduction of IGBT / AFE AC Shovel Drives

2000 World’s largest Dragline with IGBT / AFE AC Drives

2007 World’s first Gearless Dragline commissioned in China

2008 First 8750 all motions IGBT AC Geared Dragline in Australia

2008 40 m3, small shovels for India / Brazil

2009 20 m3 small shovel, 1:1 retrofit with DC in India

2014 Liquid cooled common IGBT platform for shovels / draglines

38 years Experience with AC Excavators System

SIMINE SH Overview

Shovel drive system• Active Front End Rectifier – Unity power factor, reduced harmonics• Higher Productivity - Faster Speeds, Shorter Cycle Times, 2 sec / cycle• Higher Efficiency – 10% more efficient than DC solution• Reduced Maintenance – Complete AC solution• Environmental (Dust, Ambient Temp./Altitude, Shock/Vibration)• Diagnostics (HMI, SIRAS/MIDAS)

• Portfolio – 7495 (45 m3), 7295 (20 m3), 7182 (10 m3)

• Add on option - Peak Shaver Energy Storage

Minimize the Costs Per Ton of Material Moved

SIMINE SH Inverter Cabinets

7495 with air cooled IGBTs 7295, 7182 with water cooled IGBTs

Optimized situation:

Peak Shaver reduces the peak power demand of excavators.

Rate Rise Limiter compensates for slow generator response time.

The electrical system design is optimized for power needs – reduced size, increased efficiency, suitable for weak mine network.

Allows electric rope shovel to operate with fewer generators and in locations without permanent power distribution system.

Peak Shaver Energy Storage

Peak shaver

Rate rise limiter

08/29/2013

Haul Trucks

2005 2014

1998: Prototype AC trucks for Hitachi and Liebherr - based on GTO traction equipment

2005: AC IGBT water cooled system

2000: Diesel boost trolley system developed

2007: Direct trolleyfor IGBT System

Working with several OEMs to produce truck drive systems 240t to 400t

20072000

History

Benefits

IGBT inverter system (simple and easy to maintain)• Higher efficiency than previous GTO design• Lightweight• Easy to troubleshoot

Inverter Cooling• Ultraclass (300t and above) – Liquid cooled • Small truck (240t and below) – Air cooled

Dynamic Retarding – Higher Capacity than DC• 100% Electrical Braking to ZERO speed. • IGBT Choppers are used instead of DC contractors

Modular design – commonality of parts

Benefits

Higher thermal limitations in an AC wheel motorFaster speedsLonger retards

Main blower and grid blower motors – ACLower noise level

System Cooling independent of Engine SpeedFuel Savings

Lower maintenanceNo commutator or brushes in an AC wheel motor

Designed for typical operation on 12% total grades

Key Drive System Components

• Traction Motor

• SIBAS Control

• Alternator

• Inverter Cabinet

• Gear box

• Retard Grid

• Main Blower

• Trolley Box

Siemens Truck Portfolio

Complete drive train with gear box available for 260t & 330t (Siemens)

Complete Trolley solution available for all sizes

150st X

200st X

260st X

450st X

500st X

Before 2010 After 2011

150st X

450st X

After 2013

Before 2010

150st X

200st X

450st X

500st X

After 2011

(Dual drive)

After 2013

(Single drive)(Dual drive)

New Model Introduction - Competitive solution for 300 metric tonnes

Higher grade ability More retard power More retard powerMore retard powerTrolley suitable Trolley suitableTrolley suitableTrolley suitableEasy conversion

• Propel Gradability: 26.3 %

• Retard Power: 4700 KW continuous

• Retard Gradability: -16.3 %

Trolley Truck System

Haulage Related Expenses

Maintenance Cost (~25%)Operation Cost (~ 75 %)

Overhauls

Preventive Maintenance

Fuel Costs~ 40 %

Others~ 5 %

Operators~ 15 %

Tires~15 %

Haulage Emissions

Combustion of 1 liter of diesel produces 3 kg of CO2Average fuel consumption of haul trucks is ~ 200 liters per hour

Trolley Assist for Trucks

Electric haul trucks fitted with pantographs can pull power from an overhead trolley line; the engine idles when truck on trolley

The trucks run on diesel power in the pit and around the crusher

Typical Application:Uphill haul segments (also flat segments)Established travel routesDifference between diesel and electricity cost

Trolley assist is an alternate power source

Trolley Assist Scheme

Trolley Assist Benefits

Trolley assist is a win-win situation

If the drive system can provide more power than the diesel engine, speed on grade increases proportionalto the power.

Faster uphill haul shorter cycle time higher productivity

Without trolley, more than 80% of the fuel is consumed on gradeElectricity costs less than Diesel Engine overhaul intervals doubled or tripled

Trolley assist reduces environmental impactNoise, Emissions, Carbon footprint

Trolley assist was developed during the energy crisis of the 1980s to minimize diesel fuel consumption and reduce energy costs.

Trolley System – References

Siemens Trolley Systems:

Mine Route Length

Substation Rating

Number of Substations Converted Trucks Commissioning Year

Palabora, South Africa 11,0 km 5,0 MVA 7 80 1981

Rössing, Namibia 10,0 km 3,0 MVA 7 30 1986

Gecamines, Congo 3,5 km 2,4 MVA 4 22 1986

Lumwana Copper, Zambia 4,0 km 10,0 MVA 5 32 2009

Kinshanchi, Zambia 2,0 km 10,0 MVA 2 12 2011

Trolley Truck with Siemens Drives:

Mine Technology Trucks Commissioning Year

Grootegeluk Coal, South Africa GTO 4 2001

Lumwana Copper, Zambia GTO 32 2009

Sishen Iron Ore, South Africa IGBT 94 2010

Swakop Uranium, Namibia IGBT 26 2014

Sentinel Copper, Zambia IGBT 21 2014

Trolley System Components

Overhead Catenary System

Traction Substation

Trolley Box (on the truck)

Pantograph (on the truck)

Trolley system is retrofittable

Field Results:Fuel Consumption on Grade

Top Speed Full load fuel rate Idle Speed Idle fuel rate

Engine speed fully loaded: 1900 rpm

Engine speed when idling: 750 rpm

The engine idle speed is settable as per mine request

Fuel consumption loaded engine: 450 liters/hr

Fuel consumption idle engine: 40 liters/hr

Trolley Operation

Trolley Feasibility Study

Two scenarios

Less number of trucks for same production

Increased production with same number of trucks

Mobile Mining Software Options

Software Solutions for Mobile Mining EquipmentSiRAS / Midas

Effectiveness of mining equipment plays an important role in driving mine profitability. All mining equipment benefits from:

Remote Access - Experts can remotely support mining equipment worldwide.

Health Monitoring – Send data remotely from the mining equipment and analyze them to prevent any potential failures.

Optimized Operations – Improve efficiency by eliminating bottlenecks for increased productivity and throughput.

Software Solutions for Mobile Mining EquipmentSiRAS / Midas

Service Capability

• Direct Communication to the equipment

• Access to all on-board troubleshooting tools

• Ability to monitor and modify the drive system software

• Reduces the MTTR

• Enables factory experts to join local maintenance teams.

Electrification and Automation of Trucks

Performance Improvement

– Production per day per truck per month– Fuel Use per hour per km per tonne– Tire Wear per hr per km per tonne

– Cycle Time decreased– Cycles per day increased

– %Mechanical availability increased– %Utilization increased– O&M Costs decreased

The result is lower cost per ton.

Joy Mazumdar

Business Manager

Siemens Industry Inc

100 Technology Drive

Alpharetta, GA 30005, USA

Phone: +1 (770) 740 3707Mobile: +1 (678) 327 6503

E-mail: joy.mazumdar@siemens.com

siemens.com/answers

Mobile Mining: Trucks, Trolley, Shovels Minerals Day Chile … · Mobile Mining: Trucks, Trolley,...

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