MINING TRUCKS
Liebherr T 236 truck operating under trolley at Erzberg using an innovative bar connection
shown to be 1.8 times faster on the trolley line versus diesel with up to a 21 % improvement in production . Liebherr also has the world ’ s longest trolley line - 5 km long with a 180 degree switch back running seven 100 ton T 236 trucks at the Erzberg iron ore mine in Austria . That mine has been able to achieve an 80 % GHG reduction . A 1 km extension is currently in planning as well as a 4 MW solar panel investment to complement power coming from a hydroelectric plant .
It is also unique in offering two trolley technology types - a bar connection for the T 236 as used at Erzberg and a conventional pantograph for the T 264 / T 274 / T 284 . The bar connection allows the truck to maintain contact with the overhead line around small curves and switchbacks - they are able to move both vertically and laterally by about 3 m . The pantograph is used for larger trucks that require higher voltage systems such as 1,800V and 2,600V .
Liebherr also already offers its Trolley Guidance System to assist the operator when connecting to the catenary lines which will automatically raise and lower the pantograph , optimising time on trolley , as well as steering the truck to maintain a consistent travel path while on trolley power . It is based on high precision GPS and RFID technologies and available on the T 264 , T 274 and T 284 .
For its second objective and the future , Alband said Liebherr is focussed on a modular concept that is energy type agnostic and machine application agnostic drive train technology . Zero emission design concepts will ensure that current and future equipment can be retrofitted with future technologies . Liebherr is working with its own engines to be able to run them on hydrogen , ammonia or other fuels . It is also looking at battery only trucks or FCEVs - a battery with hydrogen fuel cell hybrid . Or a smaller engine with batteries . And as already announced in June 2022 Liebherr already has a zero emission project with Fortescue - which will involve 120 trucks , representing about 45 % of Fortescue ’ s mining fleet , and with the first of the zero emissions T 264 trucks fully operational by 2025 . These will be battery trucks , using battery modules supplied by Fortescue-owned WAE . Other Liebherr truck models are expected to be
available as fully battery versions by 2028 .
WAE ’ s Dave Rawlins , Head of Engineering Technology , also spoke at The Electric Mine 2023 . As has been published previously , WAE is working with Fortescue Future Industries at FFI ’ s Hazlemere , Perth facility - firstly on a demonstrator truck retrofit of a Terex Unit Rig MT4400 truck involving a 1.4 MWh WAE battery comprised of multiple sub-packs , using a 1,400 HV architecture , along with a bespoke fast charger to deliver 30 minute high power charging . Alongside and complementing that will be the ongoing work and installation of a similar system in the first zero emissions Liebherr T 264 trucks .
For these battery truck projects Rawlins said WAE will also be deploying its Elisya battery intelligence platform integrated with advanced battery management solutions linked with fleet management solutions to enable improved machine performance in combination with safety management and extended lifetime .
Notably , in a similar way to First Mode - there is already significant interest from other mining companies in the solutions that FFI , WAE , and Liebherr are developing . Once the initial field deliveries of the zero emission T 264 trucks have been made to FMG , it is intended to offer these products to more customers .
Hitachi highlights challenges and opportunities
Also at The Electric Mine 2023 , Mining Manager of Hitachi Construction Machinery ’ s International Operations Mining Business Unit , John Schellenberg , said that its previous research going back several years had predicted more than a doubling of trolley usage globally – while it hasn ’ t yet happened – recent announcements by Glencore and BHP amongst others really do indicate a lot of increased trolley activity . That said , Schellenberg also said that its studies clearly indicate a place for both dynamic and static charging in future minesite infrastructure . But he reminded the conference that these zero emissions solutions will mean greater volatility in both power demand and power supply at mines . Electricity management will become much more important such as storing surplus power , and renewable energy source fluctuations . Faster charge rates include more system volatility . For its part , HCM along with partners including ABB is developing a full battery electric truck , firmly based on its current electric-drive truck platform . This means minimal changes to its production line but also means having to optimise battery power for a truck that was designed around space for and output from a diesel engine . It will likely start with a trolley application , based on the fact that today trolley happens to today be the best dynamic charging option . Schellenberg added that to manage battery heat generation
and maximise expected lifespan of the battery , “ the appropriate charging applications arrangement in accordance with haul circuits requirements is the key to success and it should require less DOD ( Depth of Discharge Ratio ).”
ASI Mining
Moving on to some autonomous haulage discussion , ASI Mining today is the leading provider of OEM Agnostic Autonomous Haulage System ( AHS ) solutions , as proven at the Roy Hill operation in Western Australia . Its technology can convert almost any make / model of haul truck . At the heart of its AHS solution is Mobius ® , an autonomous traffic management system for various mining applications . ASI Mining is taking clear advantage of the industry desire for agnostic solutions that offer automation benefits across a mixed fleet of vehicle makes / models . For example , ASI Mining ’ s experience with ultraclass haul trucks includes variations of the Caterpillar 793 , Komatsu 930E , Hitachi EH5000 , and others . What makes this increasingly important is the flexibility it provides mine operations to purchase the truck that works best for the operation , independent of the automation technology . This flexibility offers mine operators the ability to run mixed fleets of varying ages , makes , or models under one automation platform . It gives mine operators the ability to avoid being locked into long term truck purchasing commitments as new equipment can be incorporated into the autonomous fleet without any restrictions regarding brand , model , size , or age . That will be increasingly beneficial as new zero emission truck options emerge over time .
As more mine operations are looking into energy-efficient truck solutions such as trolley , battery electric , hydrogen , or other hybrid approaches , ASI Mining says the benefit of OEM agnostic AHS becomes even more pronounced . Drew Larsen , ASI Mining Director of Business Development : “ Most AHS programs require a long-term commitment to a specific truck OEM , meaning by choosing an AHS solution you are essentially locked into one specific brand . The alternate energy race is just beginning and now it is not clear which technology provides best results , and when these will have the maturity to be deployed into mining operations . Operators that commit long term to a truck OEM based on the AHS technology are , in effect , betting in a horse race , which is not at all settled yet . The OEM agnostic approach allows operations the ability to hedge their bet , by converting their truck today , while preserving the ability to pivot to a new make or model that may emerge as the best fit for their decarbonisation goals .”
Another interesting variation from the more common proprietary approach of the OEM
46 International Mining | JULY 2023