MINING ENGINES
parts remanufacturing for aftersales support , the facility targets to remanufacture 20,000 parts per year once fully operational , improving spare part availability and customer support in the region .
Dr Joerg Stratmann , CEO , Rolls-Royce Power Systems , said : “ We have more than 150,000 engines in the field and our service business is growing . Service is not just maintenance and repair , but also upgrades , remanufacturing and digital services for predictive maintenance .”
Remanufacturing , the company says , offers a wise lifecycle investment for customers , returning equipment to like-new condition and resulting in lower acquisition , maintenance and operation costs . “ It is also a smart choice for sustainability ; reusing existing equipment and components to save on raw materials and energy consumption compared with new engine manufacturing ,” Rolls-Royce said . “ It creates a circular economy , where instead of disposing of an engine or component at the end of its useful life , they are overhauled giving them a second or even third life .”
Stratmann continued : “ Remanufacturing is yet another part of our energy transition and sustainability story . With engines approved to run on sustainable fuels , we are significantly reducing emissions , and with remanufacturing we can get a second , third or even fourth lifetime from basically the same raw materials . “ It ’ s a total story of emissions and consumption reduction .”
Speaking of repower projects , Rolls-Royce Solutions and its Chile-based distributor Detroit Chile S . A . have recently helped lower emissions associated with Anglo American ’ s Los Bronces haulage operation thanks to a strategic engine repowering project on its 30-strong fleet of Komatsu 930E haul trucks .
For the fleet at the Chile mine , the company was looking at engines to repower the trucks that would meet the emissions targets without compromising performance . Together with Detroit Chile S . A ., the company found what it was looking for in the mtu Series 16V 4000 C05 , which , in addition to significant emission savings , also offered other benefits for operations in the South American mine , Rolls- Royce says .
This project kicked off back in January 2018 , with all 30 trucks in the fleet having now been equipped with mtu engines . An operating time of around 24,000 hours was calculated for each engine and , up to today , this fleet has surpassed 720,000 cumulative operating hours .
“ Another and undoubtedly the biggest benefit of this repower project is the cleaner operation of these engines , or the tremendous reduction of emissions ,” Rolls-Royce says . “ To comply with local emissions regulations , the previous engines required to add a selective catalytic reduction ( SCR ) system to meet Tier 4 emissions . This includes additional maintenance and extra failure points that impact truck operation , the use of Diesel Exhaust Fluid and the potential for the
catalyst to become contaminated at any time through regular operation of the truck , requiring replacement of the catalyst .
“ Since the mtu engine meets Tier 4 emissions without the SCR system , this results in less downtime , less maintenance and lower operating costs .”
With the mtu Series 16V 4000 C05 engines , Anglo American is cutting CO2 , particulate matter and nitrogen oxide emissions , according to Rolls- Royce . These engines comply with US EPA Tier 4 regulations , they consume less fuel than Tier 2 engines and still deliver the same power as previous engines .
Since the start of the repower project in January 2018 , around 9,960 t of CO2 , 91 t of particulate matter and over 3,000 t of nitrogen oxide have been eliminated , Rolls-Royce said recently . As a result , the mining haul trucks meet local emission targets and bring Anglo Americans operations at the Los Bronces mine closer to the goal of net zero .
ICE consolidation
Rolls-Royce ’ s Power Systems Business Unit recently sold its lower power range engines business to DEUTZ AG , with sales and service operations for various industrial engines in the 5- 16-litre range with a maximum power output of up to 480 kW now being carried out by DEUTZ .
This has seen DEUTZ take over the distribution of the mtu Classic series and the mtu engine series 1000-1500 , which are based on three
Managing DEF
Industrial operations worldwide recognise the challenges of managing diesel exhaust fluid ( DEF ), essential for reducing emissions but notoriously difficult to handle properly .
FillSafe DEFender from Banlaw is a unique integrated DEF transfer and tank overfill prevention solution for industrial work sites , the company says . It helps address pain points , from preventing spills and leaks to reducing fleet downtime and maintenance costs .
“ FillSafe DEFender is engineered for accuracy , reliability , safety and efficiency in DEF handling ,” Banlaw says . “ It combines the benefits of Banlaw DEFMate products , Banlaw ’ s FillSafe Power products and engineering expertise to provide a reliable , flexible and efficient solution for fleet owners .”
Some of the key benefits of the FillSafe DEFender highlighted by Banlaw include : n Prevents incorrect filling of DEF tanks : no overfills , no underfills and no tank pressurisation , ensuring each tank is filled accurately and safely every time ; n Avoids DEF crystallisation by keeping fluid temperatures above freezing point and using a closed transfer system with dry break fittings , ensuring DEF gets transferred in optimal condition ; n Ensures fluid cleanliness with specialist flush-faced DEF transfer nozzles and receivers , built with high-quality stainless steel and DEFcompatible seals for increased serviceable life ; n Prevents leaks , spills and sprays during DEF / AdBlue ® transfer , maintaining environmental safety , avoiding degradation of process
FillSafe DEFender is a unique integrated DEF transfer and tank overfill prevention solution for industrial work sites , Banlaw says
equipment and reducing clean-up costs ; n Provides peace of mind : Integrated system fault detection and ‘ fulltank level ’ status are shown using bright lights for the operator , contributing to work site safety and operational assurance ; and n Reduces the hassle of upgrading the fleet : No engineering burden and a simple , efficient-to-install DEFender kit for each vehicle saves time and guarantees the effectiveness of selected components .
100 International Mining | SEPTEMBER 2024