BAUMA 2013 Trolley Truck - industry.usa.siemens.com · BAUMA 2013 Trolley Truck April, 15-21th in Munich, Germany ... Electric haul trucks fitted with pantographs can pull power from

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BAUMA 2013

Trolley Truck

April, 15-21th in Munich, Germany


Industry Sector Page 2 April 2013

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 routes

Difference between diesel and electricity cost

Trolley assist is an alternate power source



Trolley History

1881 Werner von Siemens presents

the world’s first electric tram in

Lichterfelde

1882 Electric pit locomotives developed

for use in mines

Electric underground trolley train – approximately 1900



Trolley Assist Scheme

ALTERNATOR

DIESEL 3

RECTIFIER

///

TROLLEY BOX

(+)

(-) TROLLEY LINE

3

INVERTER

(x2)

M(x2)

~///

INVERTER CABINET



Trolley Assist Benefits

Trolley assist is a win-win situation

If the drive system can provide more HP than the diesel engine, speed on grade increases proportional

to HP.

Faster uphill haul shorter cycle time higher productivity (20% rule)

Without trolley, more than 80% of the fuel is consumed on grade

Electricity costs less than Diesel (50% fuel cost savings - $50 / 20 min)

Engine overhaul intervals doubled or tripled

Trolley assist reduces environmental impact

Noise, 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

*Barrick Gold, USA 5,5 km 6,5 MVA 7 11 1994

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

Kinshanchi, Zambia 2,0 km 10,0 MVA 2 12 2011 (Nov)

Trolley Truck with Siemens Drives:

Mine Technology Trucks Commissioning Year

Grootegeluk Coal, South Africa GTO 4 2001

Sishen Iron, South Africa IGBT 29 2010

Lumwana Copper, Zambia GTO 32 2009



Trolley Assist Challenges

Unfamiliarity

Mines do not know enough about trolley assist

Rumors of high maintenance/repair costs, high cost for moves, long payback periods,

high CAPEX for truck and wayside equipment.

Answers

Attractive payback periods of 2 - 4 years

Maintenance is required but balances with reduced engine maintenance

Trolley lines can be moved, extended, shortened; substations are movable

Mine Plan for Trolley Assist

Ideally trolley should be included in early mine planning

Simulation with life of mine trolley assist scenarios

Experts and consultants available for best planning



When does trolley assist make sense?

Trolley segments can stay in operation for significant periods of time > 1 year

The road surface can be well maintained

Adequate electrical power capacity is available

Electric energy costs less than Diesel fuel

20% of the truck cycle is on an uphill grade

Environmental Compliance: Special noise, emission requirements



One Stop Shop – Trolley System Components

Overhead Catenary System

Traction Substation

Trolley Box (on the truck)

Pantograph (on the truck)



Overhead Catenary System



Poles and Wires



Wayside Equipment



Substation



Substation Control Panel

Monitoring

Diagnostics

Controlling

Trending

Remote Operation



Screen Shot



Rectifier



Protection System



Ehouse



Aerial View



Pantograph



Relationship between Power and Speed

Truck speed increases proportional to additional power available in excess

of the existing diesel engine power

Higher speed on ramp means shorter cycle time and higher productivity

On-grade speed (v) is limited by the available power

Power Power

Tractive Effort GVW * 9.8 * Grade(%) v = ——————— = ———————————

Increased Productivity



Contributors to Mine Pollution

Neither of these environmental burdens need to be that high!

Fuel consumption and air pollution: closely correlated

CO

NoX

NMHC

Noise pollution of a ultra class mining truck: > 110 Decibels



Carbon Emissions

Economic policies for curbing greenhouse gas emissions

Carbon Tax:

Carbon taxations seeks to reduce carbon emissions by imposing a tax

Emissions Trading:

Emissions trading schemes establishes targets for specific levels of emissions through the trade in

allowance

EPA Tier 4 program: All off road vehicles with engines over 750 HP to meet Tier 4 emissions requirements

Year Category CO NHMC NOx PM

2011 Engines > 900 kW 3.5 (2.6) 0.40 (0.30) 3.5 (2.6) 0.10 (0.075)

2015 All Engines 3.5 (2.6) 0.19 (0.14) 3.5 (2.6) 0.04 (0.03)



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 fully loaded engine: 450 liters/hr

Fuel consumption idle engine: 40 liters/hr


Thank you for your attention!

Documents

BAUMA 2013 Trolley Truck - industry.usa.siemens.com · BAUMA 2013 Trolley Truck April, 15-21th in Munich, Germany ... Electric haul trucks fitted with pantographs can pull power from