MINE POWER
Going loco
Becker Warkop started developing battery-powered locomotives around seven years ago as part of a broader move towards e-mobility solutions and the upgrading of combustion engines to meet current and future standards in mining .
Its first battery locomotive was commissioned in a coal mine in 2015 , with this solution leveraging the SteepTrans system , which provides safe and profitable transport on steep slopes with small headings .
This system has enabled Becker Warkop to respond to the industry need to access ore at increasing depths with smaller-dimensioned tunnels .
The SteepTrans system can be remotely controlled and adapted for data transmission , eg to relay information to the
The newest product belonging to the Becker Warkop group of battery transport systems is the Battery-Powered Manouvering Monorail MCA-1 dispatch office or
any other room where remote control and supervision is anticipated . Operating parameters are registered in the “ black box ”, making it possible to track and reconcile any situation that occurred during locomotive operation .
Complementing the SteepTrans systems is the WRAP260 , a wireless
router access point that forms the communications backbone for a fast , stable underground network . This is “ ready for all future challenges ”, with gigabit infrastructure to accommodate and increase underground communication requirements , the company said .
The newest product belonging to the Becker Warkop group of battery transport systems is the Battery-Powered Manouvering Monorail MCA-1 . Intended for the transport of machine components and materials in underground mining areas , the monorail can operate in areas deemed as potentially explosive or hazardous – an important distinction in underground coal mines .
The advantages of the MCA-1 against the backdrop of Industry 4.0 developments , Becker Warkop says , are : n Compact dimensions – adapted to work in workshops , chambers , tunnels , etc ; n Remote control and data transfer options ; n Ability to work in tandem with other monorails ; n RFID reader authentication for monorail start-up by operator ; n Smooth drive speed regulation ; and n Built-in battery charger .
In addition to battery systems , the Becker Warkop monorail focus is on the further development of combustion systems based on the Stage III ( China III ) emission standards . To meet the needs of customers , the company has designed and introduced modern diesel monorails with a power output of 149 kW . Advantages that comes with these systems include : n Fuel economy – by using diesel engines with a common rail injection system , the economy improves ; n Limited air pollution with the injection system and a special exhaust gas cooling system ; and n Lower heat emissions to increase durability and resistance in tough mining environments . The focus of this project is on adapting the Becker-Warkop product range to higher exhaust emission standards , which has also resulted in a positive effect on the operational parameters of the diesel-powered
monorails , such as a significant reduction in diesel consumption . Above ground , Wabtec recently secured a purchase order for its first Wabtec FLXdrive battery-electric locomotive in mining , with the unit set to go to Roy Hill ’ s iron ore operations , in Western Australia .
Gerhard Veldsman , CEO of Roy Hill , said the company was committed to transforming the “ next generation of transportation ” by adopting advanced technologies that improve energy efficiency , lower operating costs and boost the company ’ s rail and mining network .
“ The FLXdrive locomotive will be the first for the region and the first for the mining industry and will improve our rail operations from the mine to Port Hedland ,” he said .
Roy Hill will receive the newest version of the FLXdrive battery-electric locomotive in 2023 with an energy capacity of 7 MWh . It is an upgrade from the 2.4 MWh prototype that was tested in revenue service `with a
Class 1 railroad in the US in 2021 . Based on the route and Roy Hill ’ s rail operations , the
FLXdrive is anticipated to reduce the company ’ s fuel costs and emissions in percentage terms by double digits per train . The ongoing use of the FLXdrive will also cut ongoing operational costs through reduced maintenance spend .
Simon Pascoe , General Manager of Engineering for Roy Hill , said : “ Our analysis with Wabtec confirms the FLXdrive locomotive is ideally suited for our rail network . It has the horsepower to operate in a heavy haul train consist pulling loaded wagons with 35,000 t of iron ore , while at the same time reducing the entire train ’ s fuel consumption . The FLXdrive also is designed to function in the extreme heat of the Pilbara region .”
Today , Roy Hill uses four Wabtec ES44ACi “ Evolution Series ” dieselelectric locomotives in a consist to pull trains that are typically 2.7 km in length . The FLXdrive will replace one of the diesel locomotives to form a hybrid consist , and recharge during the trip through regenerative braking .
The FLXdrive manages the overall train energy flow and distribution through its Trip Optimizer system , an intelligent cruise control system programmed through artificial intelligence to respond to every curve and grade of the track in the most energy-efficient way possible , Wabtec said . It is also designed with a special liquid cooling system to withstand the Pilbara heat , where temperatures can reach 55 ° C .
Wabtec says its goal is to develop the next generation of zero-emission locomotives , with a clear path to power new locomotives – and repower existing locomotives – with batteries , hydrogen internal combustion engines and hydrogen fuel cells .
Roy Hill will receive the newest version of the Wabtec FLXdrive batteryelectric locomotive in 2023 with an energy capacity of 7 MWh . It is an upgrade from the 2.4 MWh prototype that was tested in revenue service with a Class 1 railroad in the US in 2021
JANUARY 2022 | International Mining 51