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siemens.com/answersRestricted © Siemens AG 2013 All rights reserved.
Minerals Day Chile – 2015Innovative Drives for Trucks and Shovels
Mobile Mining: Trucks, Trolley, Shovels
Restricted © Siemens AG 2013 All rights reserved.I DT Minerals – Mining & Cement
Agenda
• Overview of Mobile Mining
• Shovel Portfolio
• Truck Portfolio
• Truck Trolley System
• Software Options
• Summary
Restricted © Siemens AG 2013 All rights reserved.I DT Minerals – Mining & Cement
Safety is our top priority
Safety
Reliability
Productivity
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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.
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Mobile Mining Global Center of CompetenceAlpharetta, GA – USA
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Mobile Mining Portfolio
Integrated electrical / mechanical drive systems, augmented with innovative software / technology features and services for Trucks, Shovels and Draglines
Restricted © Siemens AG 2013 All rights reserved.I DT Minerals – Mining & Cement
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)
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Electric Rope Shovels & Draglines
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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
Restricted © Siemens AG 2013 All rights reserved.I DT Minerals – Mining & Cement
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
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SIMINE SH Inverter Cabinets
7495 with air cooled IGBTs 7295, 7182 with water cooled IGBTs
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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.
Page 12
Peak Shaver Energy Storage
Peak shaver
Rate rise limiter
08/29/2013
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Haul Trucks
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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
1998
500t
2012
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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
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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
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Key Drive System Components
• Traction Motor
• SIBAS Control
• Alternator
• Inverter Cabinet
• Gear box
• Retard Grid
• Main Blower
• Trolley Box
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Siemens Truck Portfolio
Complete drive train with gear box available for 260t & 330t (Siemens)
Complete Trolley solution available for all sizes
Sm
all C
lass
Mar
ket
Ultr
a C
lass
Mar
ket
150st X
200st X
260st X
280st
320st
360st
400st
450st X
500st X
Before 2010 After 2011
150st X
200st
260st
280st
330st
360st
400st
450st X
500st
After 2013
Sm
all C
lass
Mar
ket
Ultr
a C
lass
Mar
ket
Before 2010
150st X
200st X
260st
280st
320st
360st
400st
450st X
500st X
After 2011
(Dual drive)
After 2013
(Single drive)(Dual drive)
Restricted © Siemens AG 2013 All rights reserved.I DT Minerals – Mining & Cement
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 %
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Trolley Truck System
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Haulage Related Expenses
Maintenance Cost (~25%)Operation Cost (~ 75 %)
Overhauls
Parts
Labor
Preventive Maintenance
Fuel Costs~ 40 %
Others~ 5 %
Operators~ 15 %
Tires~15 %
1
2
3
4
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Haulage Emissions
Combustion of 1 liter of diesel produces 3 kg of CO2Average fuel consumption of haul trucks is ~ 200 liters per hour
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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
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Trolley Assist Scheme
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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.
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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
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Trolley System Components
Overhead Catenary System
Traction Substation
Trolley Box (on the truck)
Pantograph (on the truck)
Trolley system is retrofittable
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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
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Trolley Operation
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Trolley Feasibility Study
Two scenarios
Less number of trucks for same production
Increased production with same number of trucks
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Mobile Mining Software Options
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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.
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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.
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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.
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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: [email protected]
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