Minerals Day Chile 2015 Innovative Drives for Trucks and Shovels

Transcription

1 Mobile Mining: Trucks, Trolley, Shovels Minerals Day Chile 2015 Innovative Drives for Trucks and Shovels siemens.com/answers

2 Agenda Overview of Mobile Mining Shovel Portfolio Truck Portfolio Truck Trolley System Software Options Summary

3 Safety is our top priority Safety Reliability Productivity

4 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.

5 Mobile Mining Global Center of Competence Alpharetta, GA USA

6 Mobile Mining Portfolio Integrated electrical / mechanical drive systems, augmented with innovative software / technology features and services for Trucks, Shovels and Draglines

7 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 High reliability Customer value Proven train technology for extreme environmental conditions High mean time between failure (mtbf) and low mean time to repair (mttr) for high availability Global service network for quick response Low Lifecycle Cost (LCC)

8 Electric Rope Shovels & Draglines

9 38 years Experience with AC Excavators System 1976 Analog SCR AC Shovel drives W 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 m 3, small shovels for India / Brazil m 3 small shovel, 1:1 retrofit with DC in India 2014 Liquid cooled common IGBT platform for shovels / draglines

10 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 m 3 ), 7295 (20 m 3 ), 7182 (10 m 3 ) Add on option - Peak Shaver Energy Storage Minimize the Costs Per Ton of Material Moved

11 SIMINE SH Inverter Cabinets 7495 with air cooled IGBTs 7295, 7182 with water cooled IGBTs

12 Peak Shaver Energy Storage Optimized situation: Peak Shaver reduces the peak power demand of excavators. Rate rise limiter Peak shaver 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. 08/29/2013 Page 12

13 Haul Trucks

14 History 1998: Prototype AC trucks for Hitachi and Liebherr - based on GTO traction equipment 2005: AC IGBT water cooled system 2007: Direct trolley for IGBT System Working with several OEMs to produce truck drive systems 240t to 400t 2000: Diesel boost trolley system developed 500t

15 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

16 Benefits Higher thermal limitations in an AC wheel motor Faster speeds Longer retards Main blower and grid blower motors AC Lower noise level System Cooling independent of Engine Speed Fuel Savings Lower maintenance No commutator or brushes in an AC wheel motor Designed for typical operation on 12% total grades

17 Key Drive System Components Traction Motor Gear box SIBAS Control Retard Grid Alternator Main Blower Inverter Cabinet Trolley Box

18 Siemens Truck Portfolio Before 2010 After 2011 After st 200st 260st X X X Small Class Market 150st X 200st X 260st 150st 200st 260st X 280st 280st 280st 320st (Dual drive) 320st (Dual drive) 330st (Single drive) Ultra Class Market 360st 400st 360st 400st 360st 400st 450st X 450st X 450st X 500st X 500st X 500st Complete drive train with gear box available for 260t & 330t (Siemens) Complete Trolley solution available for all sizes

19 New Model Introduction - Competitive solution for 300 metric tonnes Propel Gradability: 26.3 % Retard Power: 4700 KW continuous Retard Gradability: % Higher grade ability More retard power Trolley suitable More retard power Trolley Easy conversion suitable

20 Trolley Truck System

21 Haulage Related Expenses Operation Cost (~ 75 %) Maintenance Cost (~25%) 1 Fuel Costs ~ 40 % Parts 2 Operators ~ 15 % Labor 3 Tires ~15 % Preventive Maintenance 4 Others ~ 5 % Overhauls

22 Haulage Emissions Combustion of 1 liter of diesel produces 3 kg of CO2 Average fuel consumption of haul trucks is ~ 200 liters per hour

23 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

24 Trolley Assist Scheme

25 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 power than the diesel engine, speed on grade increases proportional to the power. Faster uphill haul shorter cycle time higher productivity Without trolley, more than 80% of the fuel is consumed on grade Electricity costs less than Diesel Engine overhaul intervals doubled or tripled Trolley assist reduces environmental impact Noise, Emissions, Carbon footprint Trolley assist is a win-win situation

26 Trolley System References Mine Route Length Siemens Trolley Systems: Substation Rating Number of Substations Converted Trucks Commissioning Year Palabora, South Africa 11,0 km 5,0 MVA Rössing, Namibia 10,0 km 3,0 MVA Gecamines, Congo 3,5 km 2,4 MVA Lumwana Copper, Zambia 4,0 km 10,0 MVA Kinshanchi, Zambia 2,0 km 10,0 MVA Trolley Truck with Siemens Drives: Mine Technology Trucks Commissioning Year Grootegeluk Coal, South Africa GTO Lumwana Copper, Zambia GTO Sishen Iron Ore, South Africa IGBT Swakop Uranium, Namibia IGBT Sentinel Copper, Zambia IGBT

27 Trolley System Components Overhead Catenary System Traction Substation Trolley Box (on the truck) Pantograph (on the truck) Trolley system is retrofittable

28 Field Results: Fuel Consumption on Grade Top Speed Full load fuel rate Idle Speed Idle fuel rate Engine speed fully loaded: Engine speed when idling: 1900 rpm 750 rpm The engine idle speed is settable as per mine request Fuel consumption loaded engine: Fuel consumption idle engine: 450 liters/hr 40 liters/hr

29 Trolley Operation

30 Trolley Feasibility Study Two scenarios Less number of trucks for same production Increased production with same number of trucks

31 Mobile Mining Software Options

32 Software Solutions for Mobile Mining Equipment SiRAS / 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.

33 Software Solutions for Mobile Mining Equipment SiRAS / 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.

34 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.

35 Joy Mazumdar Business Manager Siemens Industry Inc 100 Technology Drive Alpharetta, GA 30005, USA Phone: +1 (770) Mobile: +1 (678) siemens.com/answers Page 35