Brodkorb Trucktrolley Luleaminingday Handout

Truck Trolley
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26.8.2014
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Truck trolley in operation
© Siemens AG 2014
Page 2 August 2014 I&C SG RE Infrastructure & Cities; Smart Grid Division
Truck Trolley System
Main Subsystems – Overview
§ Modification of trucks enabling them to operate under trolley
§ Truck equipment with pantograph and pantograph sensor system
§ Substation
§ Overhead catenary system
© Siemens AG 2014
Basic concept
§ The power is collected from a DC overhead line by means of 2 pantographs.

§ Additional control devices apply the correct power to the motorized wheels
Overhead contact line
Trolley
control
box
Generator Controller
Motorized
wheel
Diesel
engine
© Siemens AG 2014
Overhead Catenary System
Two conductors are necessary
Each conductor is formed as an catenary,

supported using poles and cantilevers
positioned max. 40 m apart.
Typically with two contact wires and one/two

messenger wires per catenary.
All wires are automatic tensioned. The

mechanical tension of the contact wires and
the messenger wires is
12 kN / 10 kN per wire.
© Siemens AG 2014
Feeding Substation
Medium Voltage 3 Phase connection 6..30 kV.
Power per substation 2,5 … 10 MW
Feeding range 0,8 .. 2 km
The nominal voltage of the trolley system and

the power per substation depend on the
specific operating conditions at the mine.
All equipment, except transformer, is

protected from dust and moisture, housed in
an air-conditioned, hermetically sealed
container
Equipment is delivered mostly pre-installed

and ready for commissioning.
© Siemens AG 2014
Pantograph Sensor System I – Components
The pantograph sensor system ensures that pantograph

the truck operates safely under the contact
wire and that there is no damage to the aluminium pipe
containing sensor
overhead line. It consists of strips
§ the sensor strips
§ a box for electronic components
§ the display
Sensor strips:
The sensor strips are
inserted into the alu-
minium pipe, which is
mounted on the
pantograph.
© Siemens AG 2014
Benefits
Reduced operating costs

§ Energy cost savings
§ Diesel engine overhaul cost savings
Increased productivity
§ Increase in truck speed
§ Shorter turn-around times
Easy maintainability
§ Use of standard components
§ Less heating of wheel motor
Environmental benefits
§ Fuel savings of up to 30 %
© Siemens AG 2014
Economic Evaluation Examples
Truck Trolley Truck Trolley – Example

Economic Benefits Swedish Conditions
Budgetary Parameters
Empfohlen wird auf dem Titel der Einsatz eines vollflächigen
5.4.2012
Page 1 04-2012 I&C SG RE

© Siemens AG 2012
Infrastructure & Cities Sector, Smart Grid Division
25.8.2014
© Siemens
Siemens AGAG 2012
Hintergrundbildes (Format: 25,4 x 19,05 cm): Page 1 04-2012 I&C SG RE Infrastructure & Cities Sector, Smart Grid Division
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Truck Trolley Systems for Open-Pit Mining
§ Most economical on ramps,

where most of the total
energy is consumed.
§ Normal case: trucks drive

uphill at ramps with high
gradient from loading point
to unloading point.
§ Trolley is only installed on

the uphill lines. Downhill the
benefits of fuel saving or
increase in speed would be
minimal.
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Application Guidelines
Trolley Assist is worth considering if a mine has:
• High differential between electrical power and diesel fuel price

• “Long” life of ramps
• Deep pit with long ramps
• Semi-permanent ramp network
• Well constructed and maintained haul roads
© Siemens AG 2014
Contact line installation - 1
© Siemens AG 2014
Contact line installation – 2
© Siemens AG 2014
Substation installation
© Siemens AG 2014
Commissioning
© Siemens AG 2014
Truck Trolley
Standard climate and design parameters
• Ambient temperature range min/max Temp = 5°C .. + 50°C

• Maximum wire temperature 90°C
• Ice layer on structures (masts, cantilevers) No ice
• Wind speed for structural design 20 m/s
• Wind speed for conductor blow off 20 m/s
• Minimum Wind speed for thermal calculation of wire
load capacity 0,6 m/s
• Minimum radius 120 m
• Max. operational speed 30 km/h
• Nominal voltage 1500 V DC acc. to EN 50163
• Feeding voltage 1800 V ( U max1 acc. EN 50163)
!! needs to be adjusted for use in Sweden
© Siemens AG 2014
Optimum Support in all Project Phases
§ Technical advice § Electrical and mechanical § After-sales

§ Feasibility study equipment § Maintenance
§ Design concept § Civil works § Operation
§ Operational concept § Installation, commissioning, § System extension
§ Financing concepts system integration tests,
training, acceptance and
approval
Pre-award Implementation Post-completion
Consulting and System engineering, Maintenance and

system design project and interface extensions
management
© Siemens AG 2014
References – Overview
USA
Barrick Goldstrike Mine
Democratic Republic of Congo Zambia

Gécamines Lumwana
Namibia South Africa

Rössing Mine Palabora Mining Company
Company
© Siemens AG 2014
References – Details
Customer, Route Voltage Substation Number of Total Commi- Project Scope

Country Length Rating Substations Converted ssioning
Trucks
Lumwana Mining Company, 4.0 km 2,400 V 10.0 MVA 5 27 2009 Catenary system
Zambia and substations
Barrick Goldstrike Mine, 5.5 km 1,500 V 6.5 MVA 7 11 1994 Catenary system
USA and substations
Gécamines, 3.5 km 1,200 V 2.4 MVA 4 22 1986/89 Turnkey project

Democratic Republic of Congo
Rössing Mine Company, 8.5 km 1,200 V 3.0 MVA 5 30 1986 Catenary system
Namibia and substations
Palabora Mining Company, 8.0 km 1,200 V 5.0 MVA 7 80 1981 Catenary system
South Africa and substations
© Siemens AG 2014
Multi truck operation
© Siemens AG 2014
Thank You for Your Attention
© Siemens AG 2014
Truck Trolley – Example
Swedish Conditions
Budgetary Parameters
25.8.2014
© Siemens AG 2012
Page 1 04-2012 I&C SG RE Infrastructure & Cities Sector, Smart Grid Division
Truck Trolley
Economic Effects
Additional Investment
- Fixed installation for Power supply
- Upgrade of trucks for Trolley-Assist
Benefits in Operation
- Shorter round trip time by higher speed under load conditions with trolley assist
- Increased haulage capacity per truck, usable for
à Reduced no. of trucks for same haulage target
à Increase haulage of the pit with same no. of trucks
- Reduced Maintenance for Diesel Engine
- Difference in Energy costs
Other Effects
- Change in CO2 footprint, depending from source of E-Energy
- use of regenerative energy
à Economic evaluation has to cover all different influences for a specific case
© Siemens AG 2012
Swedish Budget Conditions Example
Line Parameters
© Siemens AG 2012
Truck parameters
© Siemens AG 2012
Economic input - 1
© Siemens AG 2012
Economic input - 2
© Siemens AG 2012
Specific Results
© Siemens AG 2012
Specific Results for target haulage capacity
© Siemens AG 2012
Specific results for fixed truck usage
© Siemens AG 2012
Monetary effects for defined mining capacity
© Siemens AG 2012
Monetary effects for fixed truck usage
© Siemens AG 2012
Truck Trolley
Economic Benefits
5.4.2012
© Siemens AG 2012
Truck Trolley
Economic Effects
Additional Investment
- Fixed installation for Power supply
- Upgrade of trucks for Trolley-Assist
Benefits in Operation
- Shorter round trip time by higher speed under load conditions with trolley assist
- Increased haulage capacity per truck, usable for
à Reduced no. of trucks for same haulage target
à Increase haulage of the pit with same no. of trucks
- Reduced Maintenance for Diesel Engine
- Difference in Energy costs
Other Effects
- Change in CO2 footprint, depending from source of E-Energy
- use of regenerative energy
à Economic evaluation has to cover all different influences for a specific case
© Siemens AG 2012
Truck Trolley – Sample Mine calculation
Basic data
- 2 loading areas A and B

- Common dumping area on waste heap
- All ramps with constant gradient (Bold lines)
- For Truck Trolley operation all ramps are electrified
- Load / dump time : 5/2 minutes
Line parameter example load area B to dump area
Section Length Grade Trolley
m loaded
1 300 0,0% 0
2 500 0,0% 0
3 1500 10,0% 1
4 100 0,0% 0
5 1500 10,0% 1
6 500 0,0% 0
© Siemens AG 2012
Truck Trolley – Sample Mine calculation
Technical truck parameters used for the samples
Truck type 550 t Sample truck – loading capacity 310 t
Empty weight 240 t

Total weight with load 550 t
Rolling resistance 0,02
Auxiliary power 55 kW
Wheel motor rating 4000 kW power per hour
unit Diesel Electro

Max. speed loaded km/h 50 50
Max. speed empty km/h 35 35
Power of diesel engine kW 2400 at flywheel
Power of control unit kW 5100
Effectivity traction unit 0,89
Effectivity of truck 0,898
spec. fuel consumption g / kWh 220
© Siemens AG 2012
Truck Trolley – Sample Mine
Main economic data used for samples *
Energy price level

Diesel per l 0,90 USD
El per kWh 0,077 USD
Truck costs
Price per Diesel-Truck 5000 1000 USD
Modification per Truck 500 1000 USD
Cost of fixed installation

Substation unit price 1400 1000 USD
OCL price / km 2000 1000 USD
CO2 Emission Coefficient

Electricity 0,2 kg COx / kWh
Further Input parameters

Maintenance costs
Additional Benefits for increased capacity
* All economic values are fictive values for this samples without relation to a specific mine
© Siemens AG 2012
Effects for a single round trip ( B à waste heap )
Capacity effects
Diesel mode Truck-Trolley Difference
Duration of a round trip min 37,06 29,64 -20,01%
Cost for energy per cycle USD 160,72 67,54 -57,98%
Haulage Capacity per truck t/h 501,9 627,5 25,02%
© Siemens AG 2012
Results for a required haulage capacity of 20,1 Mt/year

Necessary number of trucks 7 5

Investment 1000 USD 35000 41900
Specific costs
Energy USD / t 0,52 0,22 -57,98%
Operation USD / t 0,69 0,32 -53,18%
Annual costs
Energy 1000 USD 10408 4374 -6034
Total operation costs 1000 USD 13844 6482 -7362
Total incl. capital costs * 1000 USD 17344 10672 -6672
Return of additional Investment 1,03 Years * * Capital costs for an interest rate of 10%
© Siemens AG 2012
Results for a fixed number of 5 trucks
Haulage capacity Mt/year 16,5 20,6 25,02%

Investment 1000 USD 25000 41900
Specific costs
Energy USD / t 0,52 0,22 -57,98%
Operation USD / t 0,67 0,32 -52,02%
Greenhouse-Gas Emission
Total (CO2/haulage) kg/t 1,80 0,61 -66,07%
Annual costs
Energy 1000 USD 8548 4491 -4058
Total operation costs 1000 USD 11003 6599 -4403
Total incl. capital costs* 1000 USD 13503 10789 -2713
* Capital costs for an interest rate of 10%

Return of additional Investment 3,09 Years
0,72 Years ( with a benefit of 5 USD per t additional haulage)
© Siemens AG 2012
Conjoint use of Routes
- 2 loading areas A and B
- Common dumping area on waste heap
Separate Ways Partial sharing Common used ways

A_B A1_B A2_B
© Siemens AG 2012
Conjoint use of Routes
Amortisation time for 10 trucks with different route bundling

separate ways partial sharing common_used
Route A+B A1 + B A2 + B
Total trip length km 16,200 12,400 10,400

OCS km 6,000 4,500 3,000
Substation 12 9 6
Number of Trucks 10 10 10
haulage capacity t/h 1301 1301 1255
Invest Truck Trolley 1000 USD 30600 26400 19400

Yearly energy savings with Truck Trolley 1000 USD 8404 8404 8116
Yearly savings with Truck Trolley 1000 USD 9135 9135 8806
Return on Invest * Years 5,04 4,06 2,83
© Siemens AG 2012
Usage of route
Route from loading area A to dump area
Line parameters load area a to dump area
Section Length Grade Trolley

m % loaded
1 300 0
2 1500 10 1
3 100 0
4 1500 10 1
5 300 0
Calculation of same route for use with 3, 5 and 10 trucks
© Siemens AG 2012
Usage of route
Amortisation for route A as function of number of Trucks
Number of Trucks 3 5 10
Haulage capacity Diesel Trucks Mt / year 10,5 17,4 34,9

Haulage capacity Truck Trolley Mt / year 13,3 22,1 44,3
Investment Truck Trolley 1000 USD 12700 13700 16200
Yearly energy savings with Truck Trolley 1000 USD 2607 4346 8691
Yearly savings by Truck Trolley 1000 USD 2839 4732 9463
Return on Invest * Years 8,09 4,07 2,07
© Siemens AG 2012
Thank you for
your attention
© Siemens AG 2012

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Truck Trolley

Empfohlen wird auf dem TitelSystem

§ Modification of trucks enabling them to operate under trolley

§ Truck equipment with pantograph and pantograph sensor system

§ Overhead catenary system

§ The power is collected from a DC overhead line by means of 2 pantographs.

Overhead contact line

Two conductors are necessary

Each conductor is formed as an catenary,

Typically with two contact wires and one/two

All wires are automatic tensioned. The

Medium Voltage 3 Phase connection 6..30 kV.

Power per substation 2,5 … 10 MW

Feeding range 0,8 .. 2 km

The nominal voltage of the trolley system and

All equipment, except transformer, is

Equipment is delivered mostly pre-installed

The pantograph sensor system ensures that pantograph

Reduced operating costs

Truck Trolley Truck Trolley – Example

Page 1 04-2012 I&C SG RE

• Bild auf Master platzieren (JPG, RGB, 144dpi)

§ Most economical on ramps,

§ Normal case: trucks drive

§ Trolley is only installed on

• High differential between electrical power and diesel fuel price

• Ambient temperature range min/max Temp = 5°C .. + 50°C

!! needs to be adjusted for use in Sweden

§ Technical advice § Electrical and mechanical § After-sales

Pre-award Implementation Post-completion

Consulting and System engineering, Maintenance and

Democratic Republic of Congo Zambia

Namibia South Africa

Customer, Route Voltage Substation Number of Total Commi- Project Scope

Gécamines, 3.5 km 1,200 V 2.4 MVA 4 22 1986/89 Turnkey project

- 2 loading areas A and B

Line parameter example load area B to dump area

Section Length Grade Trolley

Truck type 550 t Sample truck – loading capacity 310 t

Empty weight 240 t

unit Diesel Electro

spec. fuel consumption g / kWh 220

Energy price level

Cost of fixed installation

CO2 Emission Coefficient

Further Input parameters

Duration of a round trip min 37,06 29,64 -20,01%

Cost for energy per cycle USD 160,72 67,54 -57,98%

Haulage Capacity per truck t/h 501,9 627,5 25,02%

Results for a required haulage capacity of 20,1 Mt/year

Necessary number of trucks 7 5

Haulage capacity Mt/year 16,5 20,6 25,02%

* Capital costs for an interest rate of 10%

- 2 loading areas A and B

- Common dumping area on waste heap

Separate Ways Partial sharing Common used ways

Amortisation time for 10 trucks with different route bundling

Total trip length km 16,200 12,400 10,400

Invest Truck Trolley 1000 USD 30600 26400 19400

Return on Invest * Years 5,04 4,06 2,83