MINING ENGINES
Computational Multi-Physics Research Section in Argonne ’ s Energy Systems division , who supervises the team working on the project with Caterpillar , said . “ We are publishing our methodology so companies can use it to design new piston bowls for themselves .”
In addition to the project ’ s simulation innovations , one of the team ’ s key contributions was its development of an industry-friendly approach , which allows companies to optimise their engine designs using their own in-house computer systems . This simplified model , based on the results of hundreds of the complex simulations , provides a similar level of accuracy while reducing the computational requirements by as much as 40 %.
Jon Anders , Principal Investigator and Senior Engineering Specialist in Caterpillar ’ s Integrated Components and Solutions division , said : “ Our work with Argonne on this project enabled the exploration of a massive design space . By working together and leveraging simulation expertise and computing resources from Argonne , with manufacturing and testing expertise at Caterpillar , we were able to optimise and test a piston on a timeline that was far shorter than would have otherwise been possible .”
Fuel cell developments
Volvo Penta may be busy with Stage V engine deployments in the mining sector currently , but the Volvo Group recently opened its first dedicated Fuel Cell Test Lab , marking a significant advancement in its ambition to be fossil-free by 2040 .
The investment will offer Volvo Group unique conditions to test and develop hydrogen fuel cell technology solutions in heavy construction machines and other applications , it said .
The dedicated lab , located at the Volvo Construction Equipment ( Volvo CE ) Technical Center in Eskilstuna , Sweden , is the first facility in Volvo Group to be testing complete fuel cell units and will , as such , be a strong contributor to the company ’ s fuel cell technology efforts .
Fuel cells work by combining hydrogen with oxygen , with the resulting chemical reaction producing electricity . The process is completely emission-free , with the only by-product being water vapour . In principle , a fuel cell works much like a battery , except that it generates its own electricity from the hydrogen on-board rather than being charged from an external source . This means it can deliver longer driving ranges and , therefore , is more feasible for long-haul transportation and heavier equipment . An added benefit of hydrogen fuel cell solutions is that they will also be free from the traditional machinery noise pollution . Without a combustion engine , hydrogen-powered machines will be comparable to the low noise
levels of the electric compact machines .
Toni Hagelberg , Head of Sustainable Power at Volvo CE , said : “ Fuel cell technology is a key enabler of sustainable solutions for heavier construction machines , and this investment provides us with another vital tool in our work to reach Science-Based Targets . It ’ s a really exciting step to accelerate the development of fuel cell solutions towards our united vision for a carbon-neutral society .”
Volvo CE sees hydrogen fuel cell technology as playing a key role within its overall electromobility ambitions , together with batteryelectric solutions and more sustainable internal combustion engine offerings . All three streams work in alignment on the journey towards a carbon-neutral society , it said .
While battery-electric solutions are ideal for urban construction and other use cases , Volvo argues , “ the size of the batteries is simply too impractical for larger machines and heavy construction equipment , which is where hydrogen comes in as a promising alternative ”.
Hagelberg added : “ Not only will the research and development carried out at the test lab be dedicated to producing fossil-free construction solutions , we will also look at how the hydrogen itself has been produced , and strive for so called ‘ green ’ hydrogen produced from renewable energy .”
Hydrogen fuel cell developments are also being explored at the Friedrichshafen plant of Rolls-Royce Power Systems where a 250 kW demonstrator is being established to test future zero-carbon energy systems to present to customers . Andreas Schell , CEO of Rolls-Royce Power Systems , said : “ We firmly believe that fuel cell technology is set to make a huge contribution to a successful energy turnaround . That ' s why Rolls-Royce sees it as its mission to assume a pioneering role in fuel cell applications . Fuel cells will form an elementary part of our product
Rolls-Royce Power Systems is currently setting up a demonstrator in Friedrichshafen to test sustainable and climate-friendly power supply based on fuel cells in the future
portfolio for sustainable solutions .”
Making the demonstrator announcement in June , Rolls-Royce Power Systems said the complex hydrogen infrastructure had already been installed , with the container – complete with its four low-temperature polymer electrolyte membrane fuel cell modules – set up .
“ Designed at the company ’ s plants in Ruhstorf , Bavaria , and Friedrichshafen , safety dictates that the container has two separate compartments for fuel cells and batteries , plus a host of power electronics ,” the company said . “ The control system has now been fully refined , cooling and air conditioning are on the roof , and a rack system enables simple maintenance , allowing individual system modules to be replaced as required .”
The energy systems , using fuel cell modules from the automotive sector , have been put through their paces on a test stand , and the Rolls-Royce engineers are more than satisfied with the results , according to Dr Peter Riegger . “ Power flexing characteristics and performance are excellent and , as expected , there are no vibrations or no loud noises ,” he said .
The next step is to connect all four demo modules together in the container and hook up the batteries and power circuit . Commissioning is slated for the second half of 2021 .
Days before making this hydrogen fuel cell announcement , Rolls-Royce ’ s Power Systems business unit announced a “ reorganised brand architecture ” where Rolls-Royce would be the corporate and employer brand , with the MTU brand – one recognised across the mining engines sector – reinforced as the “ sole product and solution brand ”.
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JULY 2021 | International Mining 71