June 13, 2013 MEMSA Annual Meeting, Clearwater, FL Peak ... · Peak Shaver/Rate Rise Limiter for Electric Rope Shovels and ... Electric Rope Shovels ... to fully operate the large

Restricted © Siemens Industry, Inc. 2013 All rights reserved. Answers for industry.

Peak Shaver/Rate Rise Limiter forElectric Rope Shovels andDraglines

June 13, 2013 MEMSA Annual Meeting, Clearwater, FL

2013-06-13

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Page 2 Koellner / Madhavarao / I US DT VSS MN

Safety is our top priority

Safety

Reliability

Productivity

2013-06-13



Sustainability

“Sustainable development is development that meets the needs of the presentwithout compromising the ability of future generations to meet their own needs”

Sustainability provides a completesolution to the problem.

The solution does not push theproblem to another area.

The solution does not necessarilylead to higher costs.

2013-06-13



Challenges in Mining – Energy Demand

Mines need effective techniques tomaintain the crucial balance betweenenergy supply and demand.

In an ideal scenario, demand forelectric power would be matchedexactly by the electric power supplied

Losses reduce the efficiency ofelectrical systems.

Increase in energy demand requires higher system efficiency

2013-06-13



Challenges in Mining – Energy Efficiency

IEA predicts global energy consumption will rise by ~65% by 2035

Focus is on

Efficient use of energy

Greater utilization of electrical power

Rapid de-carbonization of power generation

Mining industry is actively focused on energy efficiency

Siemens utilizes highly efficient integrated drive systems in Mining

2013-06-13



Current situation:

High peak demand increases thecapacity charge of the miningfacility.

The electrical system has to beover-designed to handle peakpower levels.

This is especially important ifsupply grid is weak or power isprovided from diesel generators.

High PeakDemand

Challenges in Mining – Peak Demand

Peak energy demand requires over-designed systems

2013-06-13



Solution for Cyclical Loads - Peak Shaver Energy Storage

0 5 10 15 20 25 30 35-2000

-1000

0

1000

2000

3000

4000

Time(s)

Pow

er

(kW

)

Profile Overlap

Actual

ModifiedModified situation:

Peak Shaver reduces the peakenergy demand by Excavators inMining industry

The electrical system design isoptimized for needs – reducedweight and increased efficiency

Easily able to adapt to weakermine network

Peak Shaver reduces the Peak Power Requirements of Excavators

2013-06-13



Peak Shaver – Smaller Carbon Footprint

For every 1 kWh required, 1.1 kg of CO2 isproduced through a coal energy plant.

With peak shaving, the energy storage supplies ~3 MJoules per cycle

Annually, 3*2*60*20*330 = 2,376,000 MJoules =658,152 kWh

By implementing the peak shaver, each shovel canreduce CO2 emission by 723 tonnes / year

“Green” Peak Shaver reduces Carbon Footprint of Excavators

2013-06-13



Peak Shaver / Rate Rise Limiter – Concept

PEAKPOWERDEMAND

PRIMARY ENERGYSOURCE

(Grid, Engine)

Energy Storage/Power DeliveryComponents(Ultracapacitors)

“Peak Shaver” on a Mining Shovel can reduce CO2 emissions by 723 t / year

2013-06-13



Peak Shaver / Rate Rise Limiter - Explanation

Peak Shaver :

Store the regeneration energy intoUltra Capacitors and supply thestored energy during peak powerdemand

Rate Rise Limiter :

Along with reduced peak powerdemand, the rate at which thepower required is also controlledto provide soft demand on theenergy source – e.g.: Generators

Patented technology for Excavator applications

2013-06-13



Peak Shaver / Rate Rise Limiter – Customer Benefits

Increased energy efficiency

Reduced power demand Fuel costs

Environmental compliance, i.e. loweremissions, lower noise

Able to operate Electric Rope Shovelsefficiently on locations without powergrid.

Lower OPEX

Ultra Capacitor modules are used to store and discharge energy

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Ultra Capacitor Specifications

ELFA2 ES063-125

Rated Voltage 125 VDC

RMS Current 150 ADC

Capacitance 63 F

Ambient Temp (operation) (-) 40°C – (+) 60°C

Protection Degree IP6K6K, IP6K7, IP6K9K

Mechanical Robustness Shock 100g / 0.5 ms

Dimensions in mm 604 x 240 x 435

Insulation resistance > 25 MΩ

Power and Control plugs IP 2x with Pilot contact

Very low contact resistance (welded laser connections)

Intelligent balancing during normal operation

Single cell monitoring

Histogram memory for Lifetime operation parameters

Water cooled version Under development

2013-06-13



System Hardware – Peak Shaver ON Board Solution

2013-06-13



System Hardware – Peak Shaver OFF Board Solution

2013-06-13



Off Board System - Shovel digging actual data(Generators Power Source)

Peak shaver

Rate rise limiter

100%

80%

60%

40%

20%

0%

100%

80%

60%

40%

20%

0%

T= 0s T=5s T=10s T=15s T=20s T=25s T=30s

Shovel Power

Generator Power

Ultra Caps Power

Chopper Power

2013-06-13



On Board System - Simulation data

-80

-60

-40

-20

0

20

40

60

80

100

0 10 20 30 40

Shovel Power (%)

Generator Power (%)

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Peak Shaver / Rate Rise Limiter – Capacitor Location

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Peak Shaver / Rate Rise Limiter – Capacitor Bank

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Peak Shaver / Rate Rise Limiter – Actual Field Data

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Proven Customer Benefits - Excavators

0 5 10 15 20 25 30 35-2000

-1000

0

1000

2000

3000

4000

Time(s)

Pow

er

(kW

)

Profile Overlap

Actual

Modified

Peak power reduction on Generatorsource (1 MW / second “Rate of rise)

On Shovels: 78%

On Draglines: 77%

Peak power reduction on Power Gridsource (No limit on “Rate of rise”)

On Shovels: 70%

On Draglines: 70%

Reduction of Generators required tooperate the Electric Rope ShovelsReduced by HALF

Peak Shaver reduces the Peak Power Requirements of Excavators

2013-06-13



Option : DC Draglines System Proposal

2013-06-13



Option: Motivator

Shovels:

4 MW Generators are typically used just to move the large electric ropeshovels within the mine pit.

This capacity has been proven enough to fully operate the large electricrope shovel by utilizing Peak Shaver / Rate rise limiter technology.

Draglines

Also Draglines are typically connected to diesel generator systems, whenmoved for a long distance (~25 miles)

Mobile off board Peak Shaver / Rate rise limiter system could be utilized toreduce the diesel generator capacity.

Peak Shaver / Rate rise limiter reduces the Motivator power level

2013-06-13



Thank You

??? Questions ???

2013-06-13



Contacts

Gopal MadhavaraoProduct Manager - ExcavatorsNAM RC-US I DT LD V MN

100 Technology DriveAlpharetta, GA - 30005

Phone: +1 (770) 740 3356Mobile: +1 (678) 575 0299

E-mail:[email protected]

Walter KoellnerSr. Director – Mobile Mining SolutionsNAM RC-US I DT LD V MN

100 Technology DriveAlpharetta, GA - 30005

Phone: +1 (770) 740 3480Mobile: +1 (678) 758 4125

E-mail:[email protected]

Answers for industry.

Documents

June 13, 2013 MEMSA Annual Meeting, Clearwater, FL Peak ... · Peak Shaver/Rate Rise Limiter for Electric Rope Shovels and ... Electric Rope Shovels ... to fully operate the large