Truck Trolley FINAL 2013

BAUMA 2013
Trolley Truck
April, 15-21th in Munich, Germany
Siemens AG 2013. All rights reserved.
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

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April 2013

Industry Sector
Trolley History
1881 Werner von Siemens presents
the worlds first electric tram in
Lichterfelde
1882 Electric pit locomotives developed
for use in mines
Electric underground trolley train approximately 1900

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April 2013

Industry Sector
Trolley Assist Scheme
(+)
TROLLEY LINE
(-)
TROLLEY BOX
RECTIFIER
ALTERNATOR
INVERTER
(x2)
3
DIESEL
///
M
///
(x2)
~
INVERTER CABINET
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April 2013

Industry Sector
Trolley Assist Benefits
Trolley assist was developed during the energy crisis of the 1980s
to minimize diesel fuel consumption and reduce energy costs.
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 is a win-win situation

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April 2013

Industry Sector
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
80
1981
Rssing, Namibia
10,0 km
3,0 MVA
30
1986
Gecamines, Congo
3,5 km
2,4 MVA
22
1986
*Barrick Gold, USA
5,5 km
6,5 MVA
11
1994
Lumwana Copper, Zambia
4,0 km
10,0 MVA
32
2009
Kinshanchi, Zambia
2,0 km
10,0 MVA
12
2011 (Nov)
Trolley Truck with Siemens Drives:

Mine
Technology
Trucks
Commissioning Year
Grootegeluk Coal, South Africa
GTO
2001
Sishen Iron, South Africa
IGBT
29
2010
Lumwana Copper, Zambia
GTO
32
2009
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April 2013

Industry Sector
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

Page 7
April 2013

Industry Sector
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
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April 2013

Industry Sector
One Stop Shop Trolley System Components

Overhead Catenary System
Traction Substation
Trolley Box (on the truck)
Pantograph (on the truck)
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April 2013

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Overhead Catenary System
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April 2013

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Poles and Wires
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April 2013

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Wayside Equipment
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April 2013

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Substation
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April 2013

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Substation Control Panel
Monitoring
Diagnostics
Controlling
Trending
Remote Operation
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April 2013

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Screen Shot
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April 2013

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Rectifier
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April 2013

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Protection System
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April 2013

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Ehouse
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April 2013

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Aerial View
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April 2013

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Pantograph
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April 2013

Industry Sector
Relationship between Power and Speed

On-grade speed (v) is limited by the available power
Power
Power
v = =
Tractive Effort
GVW * 9.8 * Grade(%)
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
Increased Productivity
Page 21
April 2013

Industry Sector
Contributors to Mine Pollution

Fuel consumption and air pollution: closely correlated
CO
NoX
NMHC
Noise pollution of a ultra class mining truck: > 110 Decibels
Neither of these environmental burdens need to be that high!

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April 2013

Industry Sector
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
Page 23
April 2013
Year
Category
2011
Engines > 900 kW
2015
All Engines
CO
NHMC
NOx
PM
3.5 (2.6)
0.40 (0.30)
3.5 (2.6)
0.10 (0.075)
3.5 (2.6)
0.19 (0.14)
3.5 (2.6)
0.04 (0.03)

Industry Sector
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:
Page 24
April 2013
40 liters/hr

Industry Sector
Thank you for your attention!

Truck Trolley FINAL 2013

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BAUMA 2013

April, 15-21th in Munich, Germany

Siemens AG 2013. All rights reserved.

Trolley Assist for Trucks

Difference between diesel and electricity cost

Trolley assist is an alternate power source

Siemens AG 2013. All rights reserved.

Electric underground trolley train approximately 1900

Siemens AG 2013. All rights reserved.

Trolley Assist Scheme

Siemens AG 2013. All rights reserved.

Trolley Assist Benefits

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

Trolley assist is a win-win situation

Siemens AG 2013. All rights reserved.

Trolley System References

Palabora, South Africa

*Barrick Gold, USA

Lumwana Copper, Zambia

Trolley Truck with Siemens Drives:

Grootegeluk Coal, South Africa

Sishen Iron, South Africa

Lumwana Copper, Zambia

Siemens AG 2013. All rights reserved.

Trolley Assist Challenges

Mine Plan for Trolley Assist

Experts and consultants available for best planning

Siemens AG 2013. All rights reserved.

When does trolley assist make sense?

20% of the truck cycle is on an uphill grade

Siemens AG 2013. All rights reserved.

One Stop Shop Trolley System Components

Siemens AG 2013. All rights reserved.

Overhead Catenary System

Siemens AG 2013. All rights reserved.

Poles and Wires

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Substation Control Panel

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Siemens AG 2013. All rights reserved.

Relationship between Power and Speed

Truck speed increases proportional to additional power available in excess

Siemens AG 2013. All rights reserved.

Contributors to Mine Pollution

Neither of these environmental burdens need to be that high!

Siemens AG 2013. All rights reserved.

Engines > 900 kW

Siemens AG 2013. All rights reserved.

Full load fuel rate

Idle fuel rate

Engine speed fully loaded:

Engine speed when idling: