THE LEADER VOLUME 19 • NUMBER 10
New trolley dynamics
Editorial Director Paul Moore BSc ( Hons ), MSc Email : paul @ im-mining . com
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Liebherr ’ s Innovation Lab at MINExpo 2024 outlined a range of pioneering concepts for the future of mining from a number of Liebherr ’ s product segments . One of these is a next generation dynamic charging and power transfer solution , Liebherr Power Rail .
Liebherr Power Rail features a lightweight , simple electric rail infrastructure footprint combined with an interoperable and minimally invasive side-arm type current collector . The Liebherr Power Rail builds on the proven success of the Liebherr Trolley Bar , which has been deployed at VA Erzberg iron ore mine in Austria .
It says Liebherr Power Rail offers a truck class agnostic solution designed to boost productivity and encourage the rapid expansion of zero emissions fleets . The system ’ s quick installation it says reduces costs compared to other dynamic charging technologies on the market and ensures maximum utilisation . Liebherr says it offers up to 1.8x faster speeds on a 10 % grade ( speeds of 55 km / h or 34 mph ) and relocation is relatively simple . It is also less intrusive on haul roads with switchback capability ( two lanes ). It is additionally designed for easy maintenance .
Dynamic power transfer is an effective first step towards zero emissions mine sites and beyond traditional overhead trolley assist , other dynamic offerings that also use a side-arm type of connector / current collector and electrified rail are also available including the recently announced Cat ® Dynamic Energy Transfer ( DET ) system from Caterpillar and the existing BluVeinXL solution from BluVein , the joint venture between Australia-based mining innovator Olitek and Sweden-based electric highways developer Evias . BluVein refers to its connector as the BluVein Hammer™ .
Liebherr continues to offer a conventional pantograph trolley solution across its entire truck product range including the new T 264 ( 240 t ) battery-electric truck as well as the T 264 , T 274 ( 305 t ) and T 284 ( up to 375 t ) diesel engine models . Liebherr trolley projects have included VA Erzberg ( T 236 ), FQM Cobre Panama ( T 284 ), and FQM Sentinel . Liebherr is also in the process of supplying four T 284 trucks and the trolley infrastructure for a pilot project at a large copper mine in Chile which is expected to begin operation in 2025 .
Caterpillar Inc only recently unveiled its Dynamic Energy Transfer ( DET ), described as a fully Caterpillar-developed system that can transfer energy to both diesel-electric and battery-electric large mining trucks while they are working around a mine site . It can also charge a machine ’ s batteries while operating with increased speed on grade , improving operational efficiency and machine uptime . The innovative Cat DET system provides the industry with options to support both near-term and long-term sustainability strategies .
Cat DET is comprised of a series of integrated elements , including a power module that converts energy from a mine site ’ s power source , an electrified rail system to transmit the energy and a machine system to transfer the energy to the truck ’ s powertrain .
Caterpillar says the rail system is a highly deployable , mobile solution that can be customised to customers ’ specific site layouts , including high-speed and curved haul roads , enabling higher productivity . The connecting arm can be installed on either side of a truck and on multiple truck models , providing options to fit customers ’ specific operations . It can also be used on mature or developing sites , and it can be easily moved or expanded to allow maximum mine site coverage .
Cat DET will integrate with the Cat MineStar™ Command for hauling solution , merging autonomy and electrification technologies to provide a holistic site solution .
During MINExpo , it was also announced that BHP will be the first customer to trial the DET system – this will be on both battery electric and diesel electric mining trucks at BHP sites .
The planned trials are the result of over two years of close collaboration between BHP and Caterpillar to find sustainable and viable energy transfer solutions . The trials include validating the solution in BHP Iron ore and Copper businesses , including CAT 793 fleet at Jimblebar and CAT 798 fleet at Escondida . BHP also intends to trial Cat DET as an integrated system with Cat autonomous solutions .
During a visit to Caterpillar ’ s Tucson Proving Grounds ( TPG ) in Arizona prior to MINExpo , IM Editor Daniel Gleeson witnessed just how advanced this solution is .
The company orchestrated a ‘ drag race ’ between two 798 ACs – one fitted with the DET system and another with the normal dieselelectric drive – on the “ Tinaja 10 ” test track at the facility . This haul road has been developed to showcase the system ’ s speed on grade , as well as ability to seamlessly transition on and off the DET rails . It boasts an average 10 % incline – hence the name – and will eventually stretch out to 1.6 km ( it is currently 400-m long ). At TPG , the DET system on the Tinaja 10 was powered mainly by diesel generator sets .
Like other trolley showcases before , the drag race at TPG saw the DET-enabled 798 AC beat its diesel-electric companion to the top of the ramp , with Caterpillar estimating that 1 MW more power was going into the motors of the 798 AC on the DET line than the diesel-electriconly equivalent .
Paul Moore Editorial Director paul @ im-mining . com
OCTOBER 2024 | International Mining 3