Nic Beutler Process Industries Baden-Daettwil, Switzerland, nic.beutler@ch.abb.com
According to various industry sources, including McKinsey data from 2022, the mining industry is responsible for up to seven percent of global greenhouse gas emissions (GHG) [1]. Nevertheless, mining is critical if the world is to have sufficient quantities of materials such as copper, gold, iron and a host of other metals and minerals. In view of this, the drive is on to minimize the impact of extraction in the key areas of energy and water use. To meet this goal companies are increasingly investing in clean and green energy sources, electrification of mine transport systems for people and equipment, and timely maintenance and service programs.
Technology leaders, including ABB, are working with fellow innovators, original equipment manufacturers (OEMs), truck and mining machinery builders, organized industry consortiums and, of course, mining companies themselves. ABB has increasingly called for collaboration and action in this space, highlighted by many agreements and partnerships, including with Hitachi Construction Machinery, MEDATech, Liebherr Mining Equipment, Stäubli, FLSmidth and Perenti. The aim of these agreements is to build strong relationships and an ecosystem of technology partners where experts can come together to solve some of the mining industry’s most pressing challenges.
One of the most obvious areas to focus on is the removal of fossil fuels. Reducing or eliminating diesel from heavy, fuel-consuming mining trucks and auxiliary vehicles will have a major impact. Some of the world’s largest mines use more than 100 trucks, consuming millions of liters of diesel per year. For reference, a single truck with a 100 ton-payload consumes around 400,000 liters per year [2]. Converting or substituting these machines with systems that are environmentally neutral would be no mean feat and for years was considered impossible by many authorities in the industry. Today, existing technologies can reduce diesel consumption by up to 90 percent. In fact, based on ABB’s own calculations (references available upon request), if every truck in every mine were entirely electrified, CO₂ emissions would be reduced by about 198,000 tons every day.
Streamlining mine electrification
At ABB, a portfolio focused on electrification, automation and digitization known as ABB Ability™ eMine offers an approach that leverages over 130 years of mining industry experience to combine established methodologies with cutting-edge technologies →02. Here, a pivotal part of technology development is a pilot solution known as eMine™ FastCharge. Offering up to 600 kW of power, eMine™ FastCharge was introduced in 2021 and is today the world’s fastest and only fully automated charging system for mining haul trucks. ABB is working closely with OEMs →03 to fast-track this new emissions-reducing system, which is designed to tie into and streamline a mine’s entire electrification and automation operations →04 – a major improvement over the setup of traditional mines.
Over the course of the next five to fifteen years all-electric mines will become increasingly commonplace. As this trend develops, a key factor is ensuring that equipment performs exactly as expected and that trucks can charge exactly when required. With this in mind, ABB provides OEM-agnostic charging solutions designed to fit the needs of today’s mining operations and interface with all vehicles and vehicle types. Behind this approach is a commitment to interoperable systems and proven open standards that can provide whatever solution is needed to charge battery electric vehicles (BEVs).
Nuts and bolts
eMine™ FastCharge, which has the potential to serve as a cornerstone of the transition to fully electrified mines across the industry, consists of two components: an electric charging module (ECM) and a connector terminal module (CTM). Both are fully ruggedized, modularized, and adaptable to a range of operational and infrastructure needs and are thus ready for the highest-altitude and most challenging mining environments in the world – locations where dust, moisture and dirt ingress can be a constant challenge.
Encased in a standard-footprint-size container and mounted on a removable skid, the ECM acts as the electric powerhouse of the solution. It is characterized by a mobile split-unit design that includes a powerful cooling system and heating, ventilation and air-conditioning (HVAC) protection cage, as well as a protective false floor for cabling and covered cable boxes for external connection points. Inside, it houses chargers, main switchgear, a station control system, an auxiliary transformer, and distribution panels, all mounted on shock absorbers, such that the system is safe for transit even on rough surfaces.
From the ECM, DC power is transferred to the CTM, which is an innovative module outfitted with a protective bellow and lifting table that allows it to be raised or lowered depending on the vehicle type and the height of the charger connector socket on the vehicle. It is also equipped with a station indication system that displays its status (in use, charging or fully charged, and fault), and a vehicle recognition camera system that supports quick identification of, and connection to, the vehicle’s charging outlet. Although positioning is completely automatic, it does have a human-machine interface (HMI) in case local control is needed. It also has a shock absorber and skid system similar to those of the ECM. The CTM’s electrical pin connector from Stäubli, a leading manufacturer of connector solutions, is fully integrated with a special bellow and automated shutter system within the module such that it is protected prior to, and throughout the connection with the target vehicle.
Higher charging power on the horizon In an industry where high productivity and efficiency are paramount, any viable charging solution must be fast and fully integrated. The eMine™ FastCharge pilot solution, which is designed specifically for heavy duty BEVs, provides high-power electric charging for haul trucks and is designed for the harshest environments. It can be installed anywhere and can charge any electric truck without human intervention at up to 600 kW in its first release – the highest power available in today’s market – to minimize the downtime of mobile assets. Naturally, the amount of time required for charging depends on a haul truck’s onboard battery capacity and the vehicle’s operational profile; however, in many instances a suitable state of charge can be reached within 15 minutes →05. Nevertheless, it is widely understood that the industry will need higher charging power. Work is therefore in progress to target higher power levels in the multi-MW range. In the meantime, considering that the system has a modular design, it offers a future-proof platform that adapts to higher powers and different grid connection voltages as technologies evolve.
Further to this, eMine™ FastCharge is fully digitally enabled. By digitally connecting eMine™ FastCharge, the system can be monitored and managed to optimize charging processes and energy usage in real time, thus reducing a company’s environmental footprint as well as improving its productivity at the same time.
Moving ahead, the charging operation will become an integral, additional step within mine processes. As this process takes shape, the system will need to be thoroughly managed, precisely planned, and correctly scheduled to prevent any impact on productivity, such as avoidable queuing of electric vehicles in front of the charge point. Planning will also have to ensure that sufficient electric energy is available to allow vehicles to perform their scheduled tasks in an efficient and cost-effective manner, and that charging activities are distributed across fleet and charge points in such a way as to mitigate high load peaks within a plant’s electrical distribution system.
The ABB Ability™ Operations Management System integrates mine operations in one platform and connects a facility’s workforce and equipment in real time. It also performs predictive production scheduling, automated execution, and reacts to interruptions in seconds. Among other things, the system manages the constraints of charging operations and optimizes for maximum productivity, taking other system constraints, such as power availability, mine plan and operational targets, as well as asset availability, into account.
Like other companies along the value chain, mining enterprises want to play a role in the energy transition by maximizing sustainability as well as safety and productivity in everything they do. These are the core enablers to obtaining and retaining licenses to operate in key mining countries such as Australia, Canada, Chile, South Africa and Sweden, among others. eMine™ FastCharge helps in all three areas, whereby drivers and miners do not need to be involved in the charge connection process, which is fully automated, and are supported by electric vehicles that are less noisy and more comfortable to operate.
In a nutshell, eMine™ FastCharge is a versatile system solution and a game changer that enables mining operations to be conducted sustainably thanks to:
• a common interface that works on any haul truck.
• no manual operation.
• ultra-fast charging to minimize downtime.
• a mobile system that can easily be installed anywhere.
• modular design.
• rugged design for operation in harsh environments.
• future-proof digital design.
As the trend toward full mine electrification evolves, diesel fumes will give way to clean electricity, which will help to maximize energy efficiency and the movement of persons and machines. Trucks will run at higher speeds, mining operations and their employees will benefit from CO₂-free mines, and throughput will increase even as costs decline.
Mining leaders can truly imagine a connected workplace with their people and equipment assets in synergy, ideally powered by renewable energies, such as wind, solar or hydro power. ABB will continue to bring equipment, systems and people together to make mining operations more sustainable, safe and efficient for the benefit of the environment and future generations.
References
[1] Climate risk and decarbonization: What every mining CEO needs to know | McKinsey. January 2020. Available: https://www.mckinsey.com/capabilities/sustainability/our-insights/climate-risk-and-decarbonization-what-every-mining-ceo-needs-to-know [Accessed: January 15, 2023.]
[2] Kecojevic, Vladislav & Komljenovic, Dragan. (2010). Haul truck fuel consumption and CO2 emission under various engine load conditions. Mining Engineering. 62. 44-48.
