TROLLEY ASSIST TO OPTIMISE HAULING CYCLES WITH ELECTRIC TRUCKS. Vicente E. Alvarado Planning and Development Engineer Grootegeluk Coal Mine
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1 TROLLEY ASSIST TO OPTIMISE HAULING CYCLES WITH ELECTRIC TRUCKS By Vicente E. Alvarado Planning and Development Engineer Grootegeluk Coal Mine
2 PURPOSE OF THE PRESENTATION This presentation discuss the basic analytical tools required to evaluate the feasibility of the application of TROLLEY ASSIST to mining hauling cycles. By applying trolley assist, open cast mining activities may save up to 50% in the fuel cost and improve the productivity of the fleet by 10% or more
3 INTRODUCTION
4 TROLLEY ASSIST : What is it? An engine drives the alternator to generate power on board of the truck. The power is chenneled to the wheel motors Power is collected from a DC overhead line by means of pantographs. The line propels the truck. The engines just idle along Power Capacity in a 185 Tonne Truck: Engine : 2000 HP Wheels Motors : 3100 HP COMPARATIVE DUTY Accelaration On Flat On ramp Diesel Retarding Trolley ENGINE Heavy Mild Heavy Low Low WHEEL MOTOR Mild Low Mild Heavy Heavy
5 THE OVERHEAD LINE The overhead line consists of galvanised mast poles positioned at a maximum distance of 50 m apart. The line is strung with grooved contact wire, which may be fixed directly to the poles by means of insulated brackets or may hang from a messenger cable, which is fixed to the poles by means of insulators.
6 THE TRACTION RECTIFIERS The rectifiers are sized to supply one truck permanently. In this way, the number of trucks to be connected simultaneously to the line determines the number of rectifiers to supply a specific line. This distributed scheme reduces the possibility of overloading the contact wire and reduces the voltage fluctuations experienced by the truck 1500 DC Current [Amps] Number of Trucks j Time [s e]
7 THE PERFORMANCE PARAMETERS OF THE TRUCK Speed Productivity Rate of Fuel Consumption Hauling Cost Energy Utilisation Rate Cost of Use of Electric Energy } They depend on the operational conditions of the truck Trolley Flat Retarding Loaded Flat Loading Flat Diesel Flat Retarding Empty Tipping
8 TRUCK SPEED Truck : EH4500 Electric Drive : Siemens AC Drive Gross Weight : lb Payload : Tonne Rolling Radius : 67.2 in Gear Ratio : Engine GHP : 2700 Grade : 8% Ramp + 2% RR lb 10% 67.2 in Motor Torque = = 7505 ft lb 2 12 in/ft Motor Torque [ ftlb ] Motor Torque Curves - EH4500 Euclid-Hitachi/Siemens AC Haul Truck Drive Propel, Diesel Retard, Normal Propel, Trolley 10% Grade DC Link Voltage, (on Trolley): A(max) rpm 60 min/hr 2 π 67.2 in Truck Speed in Diesel = = 14.1 KPH in/km 1450 rpm 60 min/hr 2 π 67.2 in Truck Speed in Trolley = = 26.1 KPH in/km Motor Speed [ rpm ]
9 FUEL CONSUMPTION RATE In trolley mode, the engine normally idles at about 750 rpm. In that condition, the load on the engine is mainly the cooling blower of the electrical system. This load is normally about 10% of the gross capacity of the engine. In diesel propulsion on a 10% effective grade, the engine will develop full power at maximum speed. In the case of the 12V 4000 engine, this is 2025 BHP at 1900 rpm. ENGINE IN TRUCK 730E 0.33 lb/bhp-hr 2025 BHP Fuel Rate in Diesel = = 360 LPH 1.86 lb/l 0.41 lb/bhp-hr 2025 BHP 10% Fuel Rate in Trolley = = 45 LPH 1.86 lb/l
10 Energy Utilisation in Trolley For the EH4500 truck, the maximum line voltage is limited by the capacity of the system specified by Siemens at 2400 volts maximum at the DC link of the drive. The current is limited at 1500 A. Therefore the estimated energy utilisation of the EH4500 truck in trolley mode is 3600 kw. 730E Truck Motorised Wheel Curves For the 730E Truck: Energy Utilisation = 1600 * 1450 / 1000 = 2320 KW
11 Truck Performance Measurements Truck Performance Test Type: Komatsu 730E Capacity: 185 Ton GVW: Ton Truck Performance Operation Index Unit Test 1 Test 2 Test 3 Test Performance Test on 730E Truck 48 Complete Test Date 01/08/ /08/ /08/ /08/2002 Start 12:25:28 9:56:04 10:31:16 11:01:46 Finish 12:44:58 10:28:08 10:57:45 11:37:20 Duration 0:19:30 0:32:04 0:26:29 0:35:34 Fuel Used Lts Travel Km Acceleration Time sec (Fully Loaded) Total Fuel Lts Travel Km Idling Time sec Fuel Consump Lts Av. Fuel ConsumpLph On Flat Road Time sec Fuel Consump Lts Travel Km Av. Fuel ConsumpLph Av. Truck Speed Kph On Ramp Diesel Time sec Fuel Consump Lts Travel Km Av. Fuel ConsumpLph Av. Truck Speed Kph In Trolley Mode Time sec Fuel Consump Lts Travel Km Energy KWHr Av. Fuel ConsumpLph Av. Truck Speed Kph Av. Energy UsageKW Volts - Am ps - LP KPH MW current in Amps Trolley cur in Amps Trolley volt in volt Fuel cons. in LPH Idling Truck speed in Km/h Window Trolley Window Retarding Ramp Diesel On Flat In Retarding Time sec Fuel Consump Lts Travel Km Av. Fuel ConsumpLph Av. Truck Speed Kph Loade d Empty
12 EVALUATION OF THE TROLLEY ASSIST SYSTEM Payload 185 Tonne Condition Idling Flat road On Ramp DiesIn Trolley ModFlat road Idling Flat road Retarding Flat road Cycle Loading Loaded Loaded Loaded Loaded Tipping Empty Empty Empty Summary Distance in [m] Performance with Trolley Speed [KPH] Fuel Rate[LPH E. Rate [KW] Time [sec] Fuel [Lts] Energy [KWHr Truck Productivity TPH 527 Performance only in Diesel Speed [KPH] Fuel Rate[LPH E. Rate [KW] Time [sec] Fuel [Lts] Energy [KWHr Truck Productivity TPH 473
13 EVALUATION OF THE TROLLEY ASSIST SYSTEM Payload 255 Tonne Condition Idling Flat road On Ramp DiesIn Trolley ModFlat road Idling Flat road Retarding Flat road Cycle Loading Loaded Loaded Loaded Loaded Tipping Em pty Empty Em pty Summ ary Distance in [m] Performance with Trolley Speed [KPH] Fuel Rate[LPH E. Rate [KW] Time [sec] Fuel [Lts] Energy [KWHr Truck Productivity TPH 771 Performance only in Diesel Speed [KPH] Fuel Rate[LPH E. Rate [KW] Time [sec] Fuel [Lts] Energy [KWHr Truck Productivity TPH 706
14 THE RELIABILITY OF THE SYSTEM Dispatch PowerView - Panto Utilization (Fleet) Haulpak 730E Euclid EH4500 Euclid EH3500 Total P. Fleet Total Actual Util Total Actual Util Total Actual Util Total Actual Util Aug % % % % Sep % % % % Oct % % % % Nov % % % % Dec % % % % Jan % % % % Feb % % % % Mar % % % % Apr-09 May-09 Jun-09 Jul-09 TROLLEY UTILISATION AT GROOTEGELUK MINE 100% 90% 80% 70% 60% Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09
15 CONCLUSION
16 THANK YOU VERY MUCH
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