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An Electric Future for Mine HaulageDr. Bappa BanerjeeEnergy and Mines World CongressDecember 4, 2019

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Overview• Social demands and key mining trends

- Electrification/Automation/ Connection

• Path to Electrification

- Electric Truck Roadmap

- Batteries and Energy Storage

- Charging and Trolley

• Value/Operations

- Options

- Simulations; Impacts on Fuel/Productivity

• Conclusion

Social demands and key mining trends

“Mining is not a choice – the way we mine is.”Dr. B. Banerjee

Key Trends in Mining

Automation Connection

Electrification

• Safety• Utilization• Throughput• Asset life

• Safety • System efficiency• Optimization

• Emissions• TCO• Productivity

The economic, environmental, and social benefits of sustainability

Source: A.T. Kearney analysis

Balanced Innovation Model

Viability

DesirabilityFeasibility

Ideohttps://www.ideou.com/blogs/inspiration/how-to-prototype-a-new-business

• Does this work? • Is it functionally possible in the

foreseeable future? • Will it run a shift?• Can it fit in the vehicle?• Will it work in all environments?

• Can we build a sustainable business? • What has to be true for this business to work? • What are the costs? • How will you pay for it?• Replacement frequency?• CAPEX? OPEX?• Does it lower $/ton?

• What’s the unique value proposition? • Do people want this product or service? • Does it make sense for them?• Eliminate diesel?• Flexible?• Fit the way mines operate?• Will it meet production needs?• Does it lower $/ton?

Path to Electrification

Electrification Journey

• Decouple vehicle from engine RPM• Electric Retarding…

zero wear deceleration• Gears• Bearings• Durability

Electric Drive Optimization Prime Mover Non Traction

もったいない

Electrification Journey

95%

100%

105%

90% 95% 100%

Prod

uctiv

ity v

s. B

asel

ine

Fuel Consumption vs. Baseline

Base Truck

Optimized cooling

• Parasitic cooling power matched to dynamic component needs

• Simplified ducting• Increase HP to wheels• Retard energy for

cooling

• Improved Fuel Efficiency…. $• Increased speed on grade…Tons

Electric Drive Optimization Prime Mover Non Traction

DIESEL POWERED All EV POWEREDHYBRID POWERED

Benefits:• ↓ emissions• ↓ fuel• ↑ productivity• ↑ transient response

Benefits:• Zero emissions• ↓ noise• ↓ LCC• ↑ productivity

Current configuration:• 2500 HP engine• AC alternator

Configuration:• 2500 HP engine• AC alternatror• ES Boosts Performance• ~200kWh

Configuration:• Engine, alt, radiator

eliminated• 800 – 1200 kWh ES• Trolley system or roadAnd/Or• Stationary charge system

Electric Drive Optimization Prime Mover Non Traction

240t exampleElectrification Journey

Electrification Journey Electric Drive Optimization Prime Mover Non Traction

Radiator/Alt. losses

Equivalent Electric Power

Inverter & TM Cooling & Other Loads

Truck operation loads- Dump body hydraulics- Steering- Brakes- Cab A/C

Electrification

KPI element $/ton impact Hybrid Full EV

Productivity Very High + + +Availability High + +Fuel Medium + + +CAPEX Low - - -

+ -Engine: fuel, maintenance

CAPEX – Truck, Battery Life, Stationary Charger, Fleet Size

Emissions Trolley: CAPEX, Mtce, Road & Operations flexibility (Mtce, Width)

Energy Costs Battery Disposal

Noise Training

Production

Tradeoffs

Battery vehicles and integrationBattery Chemistry Evaluation

1960’s 1970’s 1980’s 1990’s 2010’s2000’s

7T LHD – 2016(prototypes)

Li-Ion POC - 2017

Edison & 1913Electric Car

Commercial Hybrids

2020’s

Battery Electric LocomotiveCARB Demo – 2020

Battery Electric Truck(initial concept phase)

GE Energy Storage Business Launch

Beta Acquisition & NaMx Dev’t

Battery Chemistry Re- Evaluation

GRC Automotive Product Development Support

Hybrid POC’s in Marine, Loco, Mining

General Electric Company GE Transportation GE Transportationa Wabtec Company

2008 DoE Hybrid Proof of Concept

Technology Demonstrator:• Demonstrate Battery Diesel Hybrid

technology• Joint Effort between GE, Komatsu and

US DoE… Primary goal – Fuel Savings• Na-NiCl2 (ZEBRA) battery technology

(~432kWh, 18000lbs/8180kg)• Komatsu Arizona Proving Grounds• Fuel Savings 3% to 5% realized

Successful Demo Jan. 2008

Komatsu 830E-1AC

Energy Storage: Trends

• “NMC” (NMC/Graphite and derivatives) energy density and cost expected to continually improve

NMCNMCNMCNMCNMCLFPLTO

LTOLFP

NMC + DerivativesCellEnergyDensity[Wh/kg]

Start of Production [year]

Trolley

1960 1970 1980 1990 2000 20101960 1970 1980 1990 2000 2010 2017

Historic Oil Prices50 trucks installed in the 00’s

System that delivers electric power to a haul truck from an overhead line.The electric power supplements power from the engine to increase speed on grade.

What is Trolley Assist

Benefits of Trolley Assist• Increase speed on grade• Decrease fuel consumption• Charge while running

• Extend diesel overhaul schedule• Reduce emissions

• First GE systems were installed at a Cement Company in the late 1950’s• Majority of systems were installed during the 1980’s in response to the energy crisis of the 1970’s • Revitalization of Interest: Trolley is a key enabler for Battery Truck.. GHG, Environmental Impacts

History

200 GE trolley assist trucks installed in the 80’s

Stationary Charging

Stemmann-Technik• Required power transfer for trucks would exceed stationary systems developed for buses• Power requirements more consistent with ferry (marine hybrid/electric ship) chargers

Stemmann-Technik

Bus Charging Ferry Charging

LV to 4MWMV to 8MW

LV to ~600kW

Value/Operations

Configurations

Base Truck

Hybrid

240t exampleAll EV + Trolley

Stationary Charger

2500 HP + 200 kWh battery

800 kWh battery only

1200 kWh battery only

2500 HP Diesel Engine

All EV + Stationary Charging

60%

70%

80%

90%

100%

110%

120%

130%

0% 20% 40% 60% 80% 100% 120%

Nor

mal

ized

Pro

duct

ivity

(ton

s/hr

)

Normalized Energy Cost ($/ton)

Baseline

Uphill FlatDownhill

2

3

41

2

3

4

1 Hybrid• Incremental fuel and productivity

improvement on Uphill and Downhill profiles

• Highest operational flexibility

Downhill Hauls• No value to trolley• EV w/Stationary – high value even with

time penalty

Uphill Hauls• Ideal EV + trolley... Flexibility impact• EV + Stationary… delivers flexibility…

look at CAPEX

Flat Hauls• Trolley creates speed penalty…little

value• EV + Stationary – best impact… look at

CAPEX

Energy Cost ($/ton) vs Productivity (ton/hr)

Conclusion

The Future is Electric

Viability

DesirabilityFeasibility

• No ‘universal’ cell• Packaging is critical

• Substantial benefits• Investments & Viability• Technology trend

• Application, Configurationand Value

• Flexibility vs. Benefit

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Accelerating the futureof transportation