The Southern African Institute of Mining and Metallurgy

Narrow Vein and Reef 2008

S Poirier, R Lacroix and S Ouellette

The “SCOOP” ON THE WORLD’S FIRST HYBRID MINING LOADER

Sylvie Poirier, Roger Lacroix, Sylvain Ouellette

Natural Resources Canada, CANMET-MMSL

Abstract
Researchers at Natural Resources Canada (NRCan) CANMET Mining and Mineral Sciences
Laboratories (CANMET-MMSL) and Mining Technologies International (MTI) have designed and
built a hybrid diesel-electric mining loader that is the first of its kind to be developed for underground
mines.
Diesel equipment is popular because of its mobility and most mining operations are reluctant to
replace it with tethered electrical equipment despite the obvious elimination of diesel contaminants
and significantly lower heat generation (˜ 35% of an equivalent diesel). However, a diesel-electric
vehicle, being currently evaluated by CANMET-MMSL, could be beneficial. In this unit, a constant
load diesel generator feeds batteries which, in turn, powers electrical motors that drive the
equipment. In a hybrid diesel-electric unit, the constant load diesel generator can be optimized for
minimal emissions and hence lower dilution air requirements.

This paper will present the project status and the anticipated benefits for mining operations through
the application of this technology.

1. Introduction
In mining, diesel emission control is important in terms of both the health of mine workers, and the
management of the mine ventilation network. Mine ventilation is a major consumer of energy in an
underground mining operation. Any technological advancement improving the underground air
quality, including the development of low-emission vehicles, would reduce ventilation demand, and
likewise, reduce costs, and energy consumption and the associated greenhouse gas emissions.

The objective of the project is to build, test and market a 1.15-m3 Hybrid – Load-Haul-Dump (H-
LHD) prototype and verify the potential of the hybrid diesel-electric technology for handling ore and
waste rock material in underground mines. CANMET Mining and Mineral Sciences Laboratories
(CANMET-MMSL) and Mining Technologies International (MTI) are mainly responsible for
engineering design, testing and optimization, and environmental studies. Testing will be carried out at
the CANMET-MMSL Experimental Mine in Val-d'Or, Quebec. Subsequent performance testing of
the prototype is planned at three Canadian mines and one American mine. If the hybrid diesel-
electric technology proves to be reliable and efficient for underground applications, a full line of
hybrid mining equipment could potentially be developed and the technology could be marketed. This
project is a collaborative effort by the following partners:
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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

• Mining Technologies International (MTI);

• CANMET Mining and Mineral Sciences Laboratories (CANMET-MMSL);
• Société de recherche et de développement minier (SOREDEM);
• The Government of Canada;
o Action Plan 2000 on Climate Change, Mineral and Metals Program;
o NRCan’s Industry Energy Research and Development (IERD) Program;
• Hydro-Québec;
• The Diesel Emission Evaluation Program (DEEP); and
• Participating mines.

This paper describes the concept behind the “Hybridisation of a Load-Haul-Dump Mining Vehicle
Project” and presents the results of two studies carried out by CANMET-MMSL. One of the
studies estimated the potential of Greenhouse Gas (GHG) reduction anticipated following the
application of the hybrid electric-diesel technology for the Canadian mining industry. The second one
focused more specifically on the estimation of electrical energy savings for Quebec mines.

2. Hybrid Diesel-electric LHD

There are two types of hybrid diesel-electric configurations available on the market: serial and
parallel. The serial configuration has been selected for the current project because it offers the best
potential for diesel emission reduction.

The engine initially selected for the prototype was a Deutz F2L 2011. This engine is among the least
polluting available in the 15-22 kW range. Tests performed by the CANMET-MMSL Underground
Mine Environment Program showed that this engine has the lowest emissions per horsepower for all
high load operating points at speeds between 2,000 and 2,800 RPM.

The power generated by the F2L 2011 engine, when operating at 2,000 RPM with a 90% load, is 15
kW. It was estimated, through numerical simulations, that 15 kW is sufficient to accomplish most
typical duty cycles. Although the F2L 2011 engine is theoretically powerful enough, it was decided
to use a more powerful engine in the prototype. Therefore, the F3L 2011 model, a 3-cylinder
electronic EMR version of the same engine, was selected and justified for the following reasons:
• Additional power availability if the system is not as efficient as expected;
• Comparative emission levels;
• Lower fuel consumption;
• Lower demand on the batteries in peak segments of the duty cycle.

Once the trial period is completed, the engine size will be modified if proven to be overdesigned.

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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

In the actual configuration, the diesel engine is not mechanically linked to the vehicle’s transmission,
allowing the engine to operate at a constant speed. The diesel engine directly drives the hydraulic
pumps and an electric motor/generator via a pump drive. The purpose of the electric
motor/generator is to charge the batteries and supply power to the traction motor. It can also assist
the diesel engine during peak hydraulic loads.

An electric traction motor is attached directly to a 3-speed mechanical transmission. In a

conventional diesel-powered LHD, a torque converter converts engine RPM into torque when
necessary. The efficiency of the torque converter varies between 0% and 83% depending on
speed/load conditions. In the hybrid prototype design, no torque converter is required because the
electric motor can supply sufficient torque at low speed. Removing the torque converter from the
system represents a significant efficiency improvement.

Additional energy savings could have been achieved by removing the mechanical transmission if an
electric motor offering an appropriate torque/speed profile could have been found. However,
keeping the mechanical transmission offers the advantage of being able to operate the electric motor
in its most efficient operating range.

The best option for the current application is a NiMh battery pack. The main advantage of these
batteries is the high energy to volume ratio. The prototype being developed is one of the smallest
LHDs (1.15 m3) on the market and therefore space is limited. In order to obtain the required power,
three battery packs, from an existing model, are connected in parallel.

During the testing and optimization phase, adjustments and/or modifications will be made to the
prototype in order to increase its efficiency and reliability. All of the optimization will be done while
trying to keep diesel emissions to a minimum.

Furthermore, environmental studies will be carried out by comparing the level of diesel emissions
produced by the hybrid loader prototype with those of a conventional mine loader. After the collected
data is analysed, the CANMET-MMSL Underground Mine Environment Program will determine the
proper size of the exhaust purifier for an additional reduction in diesel emissions.

After the trial period at the Experimental Mine, the equipment will be tested in four different mines
for a four-month period at each mine. The companies that have agreed to participate are: Agnico-
Eagle, Kirkland Lake Gold, Goldcorp Inc. and Stillwater Mining Company.

3. Impact of hybrid diesel-electric equipment on underground mining operations

Underground mine operators are constantly dealing with diesel emission control. The development of
less polluting and less consuming equipment would represent a great opportunity to make progress on
sustainable development, energy efficiency and workers’ health. In the short and medium-term, the
hybrid diesel-electric technology applied to an underground vehicle could be part of the solution.
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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

The improvement of underground air quality could reduce ventilation demand and likewise reduce
energy consumption and the associated greenhouse gas emissions. The use of such equipment
would improve the global image of the mining industry and have a direct economic impact on
operations.

In a Canadian context, the electrical consumption required to operate a ventilation system generally
represents between 30% and 50% of the overall energy costs of an underground mine. In addition,
during the cold season, the air must be heated by using gas-fired systems (propane or natural gas).

The next two sections summarize the results of two studies carried out by CANMET-MMSL. The
first one estimates potential GHG emission reductions in a Canadian mining context and the second
one evalutes specific electrical energy savings for Quebec mines. Both studies are based on the
assumption that all diesel equipment is replaced by hybrid equipment.

3.1 GHG emission reduction implications in a Canadian context

In order to evaluate the impact of hybrid mining vehicles on GHG emissions, 44 mines listed in the
2004 Mining Sourcebook (pages 83 and 84) using trackless equipment, were considered. These
are the targetted mines for the introduction of hybrid mining equipment. The impact on GHG
emissions is related to reductions in vehicle diesel fuel consumption, electrical consumption to
ventilate the mine, as well as the fossil fuel required to heat the mine during the winter season.

In order to estimate the electrical consumption of the main ventilation system, the rated power of
each fan was taken from the 2004 Canadian Mining Sourcebook. It is assumed that all fans are
loaded to 80% of their rated power and that they run 24 hours a day for 365 days. Unfortunately, the
same data was not available to estimate the power consumption of the auxiliary fans, fuel
consumption for heating or diesel fuel consumption of the fleet of vehicles in each mine. The missing
data was estimated by using ratios calculated from data collected in 5 mines studied in detail in a
previous study (C. Kocsis, 2003). The calculated ratios are presented in Tables 1 to 3.

Table 1 – Auxiliary to main ventilation ratio estimation

Main (kW/year) Auxiliary (kW/year)
Creighton 6,818,000 27,273,000
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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

Seleine 5,174,100 8,012,300

LaRonde 9,917,350 38,615,700
Niobec 4,236,100 8,351,600
Doyon 7,803,900 35,842,300
Total: 88,949,450 35,842,300
kWh Ratio (aux/main): 1.3277
(It is assumed that the auxiliary ventilation electrical consumption is proportional to the main ventilation
electrical consumption.)

Table 2 – Propane consumption to ventilation volume ration estimation

Main (m3/s) Propane (litres/year)
LaRonde 703 2,028,570
Niobec 289 1,700,000
Doyon 345 1,262,420
Total: 1,350 4,990,990
Ratio of propane litres/ m3/s: 1.7439
(It is assumed that fuel consumption for heating is directly proportional to mine airflow.)

Table 3 – Diesel consumption to ventilation volume ratio estimation

Main (m3/s) Diesel (litres/year)
Creighton 608 1,900,000
Seleine 142 694,861
LaRonde 703 2,123,374
Niobec 289 520,000
Doyon 345 594,900
Total: 1,350 5,833,135
Ratio of diesel litres / m3/s: 1.3108
(It is assumed that fuel consumption is proportional to mine airflow.)

In the Kocsis study, it was determined that fuel cell vehicles would allow a 9% airflow reduction with
workings located below a 2,425-meter depth and 24% with workings located at a depth in the range
of 400 to 800 meters. As discussed with the author, that reduction could also be applied in mines
wanting to replace their existing equipment with hybrid vehicles. Due to the fact that there is a cubic
relationship between airflow and electrical consumption, the author estimated that electricity
consumption for the main ventilation system could be reduced by 24% to 53%. The auxiliary
ventilation system works separately and its electrical consumption cannot be reduced by the same
ratio as the main system in order to maintain proper working conditions. Therefore, the reduction in
auxiliary ventilation was estimated at 20% for all mines, which is an average value obtained for the
mines investigated in the Kocsis study. Furthermore, the reduction in mine heating is the same as
estimated for the main airflow. These reduction factors are applied to each mine in this evaluation.

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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

Another impact of hybrid vehicles is the reduction in diesel fuel consumption related directly to the
use of a smaller engine, combined with a more energy efficient system. The reduction was
estimated at 25% to 35% in a study carried out for the ‘’Institut de recherche Robert-Sauvé en santé
et en sécurité du travail (IRSST)’’. In the estimation presented, an average value of 30% was used.

All these reductions in energy consumption (electricity, heating fuel, diesel) have been calculated per
province using their specific CO2 equivalent factor to produce electricity. These factors were
obtained from the Environment Canada official website.

Assuming the replacement of the entire fleet of underground mining vehicles with hybrid vehicles, the
overall potential GHG emission reduction is estimated to be 28.4%, as shown in Table 4. This
evaluation takes into consideration the reduction in GHG emissions that is related to electricity, diesel
fuel and other fossil fuel required to heat the incoming air. The summary of GHG emission reduction
is presented by province and territory.

Table 4 - Summary of GHG emission reductions in Canada

TOTAL
Heating Mining
Electricity GHG
energy vehicle diesel
Province/Territory savings emission
savings fuel savings
reduction
tonnes/yr of tonnes/yr of tonnes/yr of tonnes/yr of
CO2e CO2e CO2e CO2e
British Columbia 80 160 300 540
Manitoba 890 4,860 9,290 15,040
New Brunswick 18,050 2,040 3,900 23,990
Nova Scotia 520 160 310 990
Nunavut 1,410 440 840 2,690
Ontario 20,100 7,100 15,210 42,410
Quebec 40 2,570 5,320 7,930
Saskatchewan 9,700 1,230 2,350 13,280
Northwest Territories 280 80 150 510
51,070 18,640 37,670 107,380
47.6% 17.4% 35.0% 28.4%

Energy savings and GHG emission reductions are mainly associated with the ventilation system
electric al consumption (47.6%) and with a reduction in diesel fuel requirements (35.0%). Fuel for
heating has a less significant impact on emission reductions because the fresh air is heated only
during the cold season. It is important to mention that there are a few Canadian mines that are
cooling air during summer months to improve working conditions. This factor was not considered in
this evaluation because of the lack of information and in view of the fact that only a few mines use a
cooling system.
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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

3.2 Specific electrical energy savings estimated for Quebec mine s

A total of ten (10) Quebec mines were asked to provide recent data on their ventilation systems and
their diesel equipment in use. While assuming that all underground diesel equipment is replaced by
hybrid equipment, it was also assumed that all types of equipment had the same energy consumption
patterns as LHDs. That assumption should be studied in depth for all types of vehicles used
underground in order to obtain a higher degree of accuracy in terms of ventilation requirements.

According to a CANMET-MMSL study, the airflow could be reduced by 35% using hybrid
equipment if no other factors needed to be considered. Generally, as the mine gets deeper, heat
becomes the limiting factor for airflow requirements. Even when the equipment is emission-free, a
minimum airflow must be maintained to eliminate blast fumes and dust, and to control heat levels and
maintain air speed above 0.5 m/s.

In order to calculate the electrical consumption reduction associated with airflow reduction, it is
important to estimate the electrical consumption of the primary and secondary ventilation systems
separately according to the specific configuration of each mine. This detailed exercise was done in
the Kocsis study for two of the Quebec mines. For the other mines, the electrical consumption was
estimated as a function of the nominal force, the load and the annual operating time of the fan
provided by the participating mine operators.

The results illustrated in Table 5 show a 20% reduction in ventilation requirements brought by the
introduction of hybrid diesel-electric equipment. Consequently, a reduction in electrical consumption
between 18% and 41% can be achieved, depending on the mine. The overall yearly reduction was
estimated at 49.33 GWh for Quebec mines.

Table 5 – Estimation of the reduction in electrical consumption for underground Quebec

mines
Mines Airflow Potential Electrical consumption reduction
reduction
Primary Secondary Cooling Global Global
m3/s % ventilation ventilation
% % % % GWh
Casa 330 20 45 20 32.3 5.81
Berardi
Doyon 360 22 53 19 25.1 1.09
Goldex 189 20 52 20 41.3 3.64
(projection)
Lapa 142 20 45 20 32.8 5.95
(projection)
LaRonde 703 14 36 16 14 18.7 11.72
Niobec 289 20 45 20 28.4 3.58

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The Southern African Institute of Mining and Metallurgy
Narrow Vein and Reef 2008
S Poirier, R Lacroix and S Ouellette

Seleine 142 20 45 20 29.8 3.93

Bell 1 153 20 n/a n/a n/a n/a 3.25
Kiena 1 24 20 n/a n/a n/a n/a 0.50
(projection)
Total : 49.33
1:
Electrical consumption estimated from the average value obtained from the other mines.

4. Conclusion

The introduction of hybrid equipment in the mining industry would be beneficial to the health of
workers, the profitability of operations and the environment. The hybridisation of a Load-Haul-Dump
(LHD) mining vehicle is progressing well. The prototype should be ready for testing at the
CANMET-MMSL Experimental Mine at the end of June 2008. The trial period will allow to
evaluate and improve the efficiency and reliability of the prototype, while keeping diesel emissions to
a minimum.

Based on the available data, the introduction of hybrid diesel-electric equipment in underground mines
has the potential of reducing GHG emissions by 32%. This represents 119,930 tonnes a year of CO2
equivalent for the Canadian mining industry. The potential improvement is mainly associated with the
reduction in electrical consumption related to mine ventilation (47.6 %) and in fuel consumption (35.0
%) by using smaller engine.

Regarding the specific study on potential electrical energy savings in Quebec mines, results showed
reductions ranging between 18% and 41%, depending on specific mine configurations.

5. References

2004 Mining Sourcebook, Canadian Mining Journal, pp. 83-84 and pp. 96-98.

C. Kocsis, CANMET-MMSL, 2003, Ventilation Benefit Analysis for Canadian Mines, Fuel Cell
Loader Project.

S. Poirier, R. Lacroix, LMSM-CANMET, 2006, Potentiel en économie énergétique électrique et en

réduction de gaz à effet de serre pour les mines souterraines du Québec.

S. Poirier, R. Lacroix, CANMET-MMSL, 2006, Hybridisation of a LHD Mining Vehicle – Project

Update and Estimation of Potential GHG Emission Reductions in a Canadian Mining Context.

Websites:
www.ec.gc.ca/emsinfo/pmsgoana_e.htm, Table A.1.
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The Southern African Institute of Mining and Metallurgy
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www.ec.gc.ca/pdb/ghg/inventory_report/2003_report/ann10_e.cfm#sa10_1
http://www.ec.gc.ca/emsinfo/pmsgoana_e.htm

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