MINING TRUCKS
EPCA ’ s converted Cat 777D at The Electric Mine 2024
kW diesel engine has been switched out with a 1,000 kW electric motor & 2 MWh of Xerotech batteries . The conversion was done at its Hazelmere workshop in WA . Clayton Franklin , Founder and Chief Engineer at EPCA told the conference in terms of meeting net zero targets : “ EPCA solves this with 0 % emissions reducing costs and we give a total turnkey solution of a truck , a charger and the solar farm ... we model it extensively in ANSYS with Twin Builder and we know exactly how our truck performs on any client ’ s mine with a fair degree of accuracy . We then took the 777 , stripped it , removed the diesel , and then installed the electric powertrain . It ' s a simple solution built on a reliable Caterpillar chassis - 90 % of this truck is Caterpillar .” He said the electric motor is three times as efficient as the diesel engine : “ It has significantly more horsepower and the horsepower that it gets doesn ' t suffer from the parasitic loads of a diesel engine .” Plus it weighs 450 kg versus the 5.9 t 3508B engine taken out .
First Mode trailblazing continues
First Mode has been something of a trailblazer in decarbonisation solutions for mining trucks . It works on the basis that the most sustainable mining truck is the one you already own and says its retrofit power systems can extend the life of existing fleets with an integrated design that maximises flexibility and interoperability .
In mining , a typical heavy-haul truck burns about 1 million litres of diesel fuel per year and remains in continuous operation for 10-15 years . Across First Mode ’ s customer market , it estimates that over 13,000 of these trucks are in global operation , releasing 35 million metric tons of carbon dioxide annually – the equivalent emissions of 8 million passenger cars per year .
To help the sector achieve its goal of 85-100 % emissions reduction by 2050 , First Mode ’ s Path to Zero™ product line begins with a low-risk pack , which is also utilised in the FCEV and BEV systems .
In the HEV , the engine remains unchanged , allowing the vehicle to operate regardless of the battery pack status . The choice of battery pack is contingent upon the truck model , with a Komatsu 930E HEV retrofit carrying a 375 kWh LTO battery pack .
CEO Julian Soles told IM : “ Most major miners have pledged an 85-100 % reduction in greenhouse gas emissions by 2050 . First Mode not only has the mining experience and technical capabilities to help miners achieve these targets , but also rapidly de-risk innovation for them – as demonstrated by our DT74 proof-of-concept fuel cell electric vehicle ( FCEV ) developed in hybrid electric vehicle ( HEV ) retrofit that requires collaboration with Anglo American , and more no infrastructure changes and uses regenerative recently , our retrofit product line expansion to braking to decrease truck fuel use and carbon include hybrid diesel , full battery , and the next emissions by up to 25 %. From there , the HEV ’ s generation fuel cell electric vehicle power interoperable ‘ feed forward ’ design enables systems , which leverage rather than discard mining companies to complete their fleet customers ’ existing fleets . Customer confidence conversion to zero-emissions using First Mode ’ s is high , with purchase orders already placed for full battery or next-generation hydrogen fuel cell our HEV product , because no other modular EV drivetrains at a pace and timeline that they power architecture in the market today can control . immediately convert existing fleets to hybrid EVs
Before 2023 was out , First Mode ’ s proof-ofconcept Hybrid Electric Vehicle ( HEV ) mining systems , bridging customers to what ’ s next in
and then either our full battery or fuel cell EV truck was successfully demonstrated in a clean energy at a pace that they control .” controlled test area at its proving grounds in
He adds : “ Our focus this year on our diesel Centralia , Washington , USA . Proving that it works hybrid electric vehicle ( EV ) retrofit reflects our was just the first step – 2024 will see the start of customers ’ need for a low-risk , cost-effective pilot-scale deployments for the HEV solution as option that immediately reduces their part of First Mode ’ s Path to Zero program , with greenhouse gas emissions as broader supply commercial availability scheduled for 2025 . chains for both clean grid electricity and clean
The HEV serves as the first step in Path to Zero hydrogen continue to grow . Still , as much as we by reducing emissions by up to 25 %, and it says are focused on our hybrid EV , we remain also provides customers with a ‘ seamless committed to spurring the market for zeroemissions haulage solutions . Since these transition ’ to the Fuel Cell Electric Vehicle ( FCEV ) and Battery Electric Vehicle ( BEV ) by leveraging solutions can vary in their upfront systems the existing retrofit work from the HEV . This requirements , we ’ re also diligently working to transition is facilitated by the shared HEV battery solve – for example – the challenges of fuel cell
First Mode ' s low-risk HEV retrofit requires no infrastructure changes
36 International Mining | JULY 2024