MINING ENGINES
Optionality in the face of uncertainty
The internal combustion engine is far from dead , but the fuels that power these workhorses are set for a change . Longer term , and in line with the Paris Accord , the mobile equipment power options are vast with no silver bullet having yet emerged , Dan Gleeson reports
Mining companies are facing some difficult decisions in the next few years as their ageing fleet matures to a point where they need to carry out substantial rebuilds or purchase new machines .
At the same time as this , the companies that miners and OEMs rely on for engines are encountering their own difficulties with regards to what fuels they certify for their products and what their future power options should be .
Both sides are after commercial optionality that is difficult to provide in a time of uncertainty such as now .
This has seen engine providers and specialist engineers offer interim solutions that can allow mining companies to reach their 2030 emission reduction goals , while preparing for a more fundamental shift in the power dynamic with net zero aims a decade or two later .
This is asking a lot of an industry that has become used to utilising diesel in its internal combustion engines for a century or more , but , as IM learnt , it is up for the challenge .
Cummins ’ Path to Zero
“ We ’ re right now on the leading edge of a transition between the way things were with fossil fuel-based powertrains and something in the future that is going to be non-fossil fuel based ,” Robert Schaefer , Director , Mining Innovations & Growth Initiatives at Cummins , told IM .
This transition is being felt all over the industry , including at Cummins , which has developed a “ Path to Zero ” philosophy towards decarbonising the various industries it works with .
As well as investing in a whole host of new long-term transition solutions from electric power to proton exchange membrane ( PEM ), solid oxide ( SO ) hydrogen fuel cells , and the supporting electrolyser infrastructure , Cummins is making significant investments in helping miners start their decarbonisation process today .
Recent US Tier 4 Final / EU Stage V engine releases aimed at providing ‘ cleaner ’ dieselpowered solutions for mining applications include the QSK95 , the QSK78 Sprint and the QSK38 .
The QSK95 comes with 2,837-3,281 kW of power and 15,245-17,653 Nm of torque , delivering an “ optimum power-to-weight ratio for 400 ton ( 363 tonne ) haul trucks ”, Cummins says . This power rating is built on providing increased fuel efficiency and , on average , a 15 % better life to overhaul , leading to a longer engine lifespan with fewer overhauls .
Cummins has already put this engine to the test at a high-altitude mining application in Latin America on board a Komatsu 980E , with Schaefer saying the engine performance , cycle time and cost of production metrics had all proven “ positive ”.
Across the company ’ s circa-12 million engines operating in the field , Cummins is also increasingly looking at non-diesel fuel options .
“ We ’ re approving use of paraffinic fuels blended with diesel ,” Schaefer said , adding that there are significant greenhouse gas ( GHG ) reduction benefits to be had with use of
Cummins has developed a “ Path to Zero ” philosophy towards decarbonising the various industries it works with
approved formulations of , for instance , hydrotreated vegetable oil ( HVO ).
“ As long as the fuel to be used meets the required standards , miners can incorporate a 25 % blend into their mix , which will most likely provide a GHG reduction of 17-21 %,” he said . “ With the prices of paraffinic fuel where they are now – and where they are going be for the next several years – using 100 % paraffinic fuel is not yet TCO ( total cost of operations ) positive . Blending can help miners hit their interim targets while still focusing on the operating costs .
“ This means if you have any mining machine out there with a Cummins engine currently running on diesel , you can – without any modifications to the vehicle – change the fuel source and reduce your carbon footprint today .”
For mining companies looking at interim steps ahead of their longer-term 2030 , 2040 and 2050 goals , such GHG cuts are appealing , providing proof to various stakeholders that they are serious about decarbonising their operations .
According to Schaefer , Cummins is carrying out testing on higher blends of paraffinic fuels in its diesel engines for mining applications .
“ Ultimately the goal is to get to 100 % on all engines ,” he said . “ By the time we get to this point with our mining engines , and we can recommend it to our customers , we are hopeful the cost of these fuels – buoyed by increased global supply and investment in new paraffinic fuel plants – will mean it is a viable option for our customers .”
As it stands , every Cummins diesel engine below 15-litre capacity is already approved for 100 % HVO use if the fuel hits the required international standards .
JULY 2022 | International Mining 51