Tag Archives: diesel

Purify Fuel and Solvay launch new additive blend for diesel-powered engines

Environmental, Mine ventilation, Mining consumables, Mining equipment, Mining services, Sustainable mining, , , , , , , , ,

Purify Fuel and Solvay say they have developed a nanotechnology-based fuel additive blend designed to improve fuel efficiency, increase power and reduce harmful emissions in existing diesel-powered engines.

First marketed 18 years ago, Solvay EOLYS Fuel Additives, an essential element in Purify Fuel’s fuel additive formulations (nanO2®), have been used in more than 16 million new engines with similar nanotech combustion catalysts. They are designed to reduce greenhouse gases and regulate emissions while improving fuel efficiency.

Through this effort, Purify Fuel’s nanO2 Fuel Additive Blends leverage Solvay’s nanotechnology expertise to create diesel fuel additive blends that reduce harmful emissions while improving fuel efficiency, Purify Fuel said. “The nanO2 Fuel Additive Blends can be introduced without any upfront costs to the 400 million diesel engines not already equipped with pollution control devices,” the company said.

John Carroll, CEO of Purify Fuel, said: “It is exciting to be part of this partnership, and to be working on a technology that will make meaningful impacts to transform the rail, marine, fracking, mining and power generation industries, leading to a significant reduction in harmful emissions on a global scale.

“While we all know the world needs faster conversion to renewable sources, there is still a great deal of infrastructure that is operating on diesel that will take years to convert. We have a proven solution that is available now, that reduces costs, and improves air quality.”

Sebastien Meric, Executive Vice President of Solvay Special Chem, added: “We are pleased to combine our 30 years of expertise in technologies for exhaust emission control & fuel efficiency with Purify Fuel to tackle both increasing emission and fuel consumption challenges.”

This global technology, which will be available in North America, Europe, Africa and Asia, provides advantages, according to the company, such as:

  • Reducing harmful emissions by up to 35-55%;
  • Improved fuel efficiency offsets the cost of the emissions-reducing fuel additive, and;
  • Operator savings of 6-12% on net fuel costs.

Carroll added: “If operators of existing engines implemented nanO2 to reduce emissions by 30%, it would have the equivalent effect of removing 100 million diesel trucks off our roads – buying the world more time to implement smart pollution control technologies.”

Cummins powers up for the future of mining

Environmental, Mine ventilation, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , , , , , , ,

Mining operations are embracing the opportunities created by new technology, from automation and electric vehicles to renewable energy, but what can traditional fossil fuel power generation contribute to this technology-led evolution of mining? Craig Wilkins, Director Prime Power at Cummins, explains how natural gas power is key to meeting the industry’s power needs in the coming decades.

Many mining operations take place in remote parts of the world where access to large electric utility feeds is either unavailable or requires significant investments in electrical transmission and distribution. These same sites may also have little or no access to pipeline gas, or experience a variation of natural gas supply. In addition, they are operating in the most extreme climates imaginable, faced with blistering heat, the wettest humidity and high altitudes.

Therefore, the need to secure a reliable prime and peaking power supply to keep production up and running 24/7 is paramount.

Cummins has responded to this challenge with a significant investment into the natural gas arena with the launch of its HSK78G gas-powered generator, a flexible prime power solution for heavy-industry installations in the most extreme environments. Its extreme engineering is designed to push the boundaries of performance and challenge the perceived limitations of natural gas generators for mining operations. It has barrier-breaking fuel flexibility, able to burn pipeline natural gas, flare gas and biogas, even the lowest BTU methane down to 40MN, and free fuel sources, with high efficiency and low emissions.

The investment on the HSK78G comes as the power market across the globe is changing. Technological advances in renewable energy and its application with batteries as part of modular power networks, tend to dominate the future of power generation. The concept is flexible, scalable and able to power entire cities as well as remote off-grid installations – such as mines. So why invest in traditional natural gas power?

Gas vs diesel

Miners continuously look for ways to lower their cost of production.  One of the major sources of cost for an open-pit mine site is fuel.  Some mines have access to an un-interruptible supply of natural gas that offers them a lower total cost when compared to diesel. 

Although technological advancements in natural gas storage and filling have yet to yield an economical replacement to diesel engines in mobile mining equipment, prime power generator sets are quickly moving towards lean burn, natural gas technologies. Lean burn gas powered generator sets use twice as much air in the fuel/air mix than required for total burn, which lowers burn temperature and NOx output, ensuring compliance with emission regulations.

Due to increasing emissions limits being adopted for generator sets, diesel generators sometimes are limited in their use. Lean burn, natural gas generator sets typically have ten times lower NOx than diesel equivalents (250-500 mg/Nm3 for natural gas compared to 2,500-3,000 mg/Nm3 for diesel.) Also, lean burn particulate levels are almost zero, so meeting location specific emissions regulations can be far easier across a global perspective.

Power generation fuel flexibility

Technological advances in design, running in tandem with market change, will result in gensets that can use fuel efficiently in varying qualities. This innovation is demonstrated by our new HSK78G, which delivers high electrical efficiency of up to 44.2% (50 Hz) and 43.5% (60 Hz) on a range of pipeline natural gas down to 70 methane number (MN) without impacting power output and efficiency.

Ultimately this fuel flexibility empowers operators to derive clean power from what would otherwise be regarded as waste products, at worst emissions. The technology for smarter and cleaner power solutions is speeding up and adoption will continue to grow as more mines embrace its capital expenditure (capex) and operational expenditure (opex) advantages.

Engineered to extremes

A further challenge for the mining operation is the environment in which the generator set operates. As engines operate, they produce heat and tend to be more sensitive to the ambient temperature levels. A generator’s ambient capability is defined as the maximum temperature at which it can operate without experiencing a loss of efficiency and it is an essential factor for customers operating in such extreme environments.

Without an engine capable of meeting high ambient temperatures, customers risk having to derate their engine, which can lead to reduced power efficiency and shorter operational life from the generator or having to stop it altogether. The HSK78G has been designed to operate at the highest ambient temperatures in the most remote locations, all far from the closest grid, offering full power capability without derating at 50°C (122°F) and 500 m (1,640 ft).

Gas vs renewables

The focus of many customers is to achieve the optimum levelised cost of electricity (LCOE) given the availability of different technologies which are suitable for their application. This can range from 100% gas generation through to a balanced mix of renewable sources such as wind or solar, and complementary storage technologies that leverages the reliability of gas generation to ride through periods where renewables are limited by their cyclical nature. The technology mix utilised will drive the different capex and opex cost scenarios that will ultimately affect the LCOE.

Improvements in gas engine technology, such as in the new HSK78G engine from Cummins, have pushed maintenance and overhaul limits well beyond the traditional envelope, thereby lowering opex costs over time. Jointly, we will continue to see cost reductions in storage and battery technology as volumes increase. For the near future, however, miners will continue to look for mixed technology to balance their capex and opex trying to achieve the lowest LCOE for its sites.

Preparation for electrification

As much as 40% of an underground mine’s energy outlay is spent on powering ventilation systems to remove pollutants from tunnels. Reducing the use of fossil fuels underground could have significant cost benefits for underground mines. In addition, The International Council on Mining and Metals have set their vision to provide solutions for minimizing the impact of underground diesel exhaust by 2025. As more underground mining vehicles and equipment contemplate the potential benefits of electrification, Cummins will continuously invest in power systems that will be ready to support such power need and respond to any changes in the mining industry

The right technology choice

In the future most power systems will require a mix of technologies that are specifically suited to their environment, emissions zone and location.  Natural gas power offers mining operators an efficient and proven and prime power solution. From Cummins perspective, a lot of investments are made in new gas engineering technology, which are demonstrated with the HSK78G gas series. Additional product investments are being made within the 500-1 MW space, which will be released later this year, offering a comprehensive gas product portfolio to meet all market requirements. Progressively stringent global emissions standards are also driving Cummins investment into a variety of technologies – natural gas, diesel, batteries and fuel cells, to ensure that customers have the right power for the right application.

Cat’s DGB dual-fuel technology cuts costs, emissions at La Herradura gold mine

Environmental, Equipment maintenance, Mine operation news, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Precious metals, Sustainable mining, , , , , , , , , , , , , , , , ,

Caterpillar has been showing one of Mexico’s biggest gold mining operations that its Dynamic Gas Blending™ (DGB) technology can provide savings on fuel costs and emissions while maintaining the same performance, payload and productivity of its diesel haul trucks.

The mining OEM and its Mexico-based dealer, Matco Cat, have been working with Fresnillo’s Penmont division to convert its entire fleet of large mining trucks at the La Herradura open-pit mine, in Sonora.

Caterpillar’s dual-fuel DGB technology, which has accumulated 10 million hours in the oil and gas industry since 2013, works by blending lower cost liquefied natural gas (LNG) with diesel fuel, according to Cat.

The resultant improvements in fuel, emissions and maintenance can add up to millions of dollars each year in cost savings, Cat said.

La Herradura, since 2016, has acted as a great case study for the technology given it has more than 250 Cat trucks and the operation hauls at least 25 Mt of volume per quarter (based on Fresnillo’s most recent Q4 production results).

In addition, the company has been looking for ways to “produce (gold) in a sustainable manner”, Fresnillo’s Abel Villa said in a recent Cat customer story.

According to Steve Igoe, Commercial Manager for Caterpillar’s Gas Engine Business, the benefits of DGB technology include, primarily, a lower cost per tonne, realised through a lower fuel cost. “DGB truck operation with LNG has proven very beneficial to La Herradura, and this is why they have decided to convert their entire fleet,” he said.

“Typically, LNG is 30% lower than the price of diesel. And, on a typical fleet at a mine, that adds up to millions of dollars a year,” he said. “And the trucks maintain the ability to operate 100% on diesel.”

Cat estimates a fleet of 100 trucks spends approximately $60-70 million/y on diesel fuel. With 65% displacement to LNG using DGB, that fleet could save $13 million/y on fuel alone.

DGB can also bring about a 30% cut in emissions compared with diesel-only operation – another important saving for mining companies looking at sustainability.

Trials during 2016 and 2017 of the technology at a gold mine in Turkey and a phosphate mine in the US have proven these claims.

For instance, the Turkey gold mine has retrofitted DGB technology on Cat 150-ton (136-t) 785C haul trucks and, since installation, has reached an average 70% average fuel displacement in addition to an operating cost reduction of $30/h.

Fresnillo’s Villa said La Herradura had gone further than this in terms of displacement.

“Initially when we started the project, the substitution rate was 70:30. We evaluated the results and changed the substitution to 85:15,” he said. This is close to the peak substitution rate Cat typically recommends.

Villa continued: “We have an average reduction of 70% in diesel consumption. We also considerably reduced the amount of emissions. When we compare both diesel and gas, the operation is the same.”

Cat said it observed a less than 1% difference in speed, payload and gear shifting, plus a 30% reduction in fuel cost, during one customer’s 5,000-h DGB trial.

La Herradura has also seen no unexpected maintenance issues during the trials, according to Fresnillo’s Enrique Leal. This is in keeping with Cat’s focus on reliability and productivity, with the company saying it has tallied zero hours of unplanned downtime.

So far, La Herradura has retrofitted 31 of its 785C haul trucks and a significant number of 240-ton (218-t) 793D trucks with the DGB technology.

Fresnillo’s Villa said the operation also plans to partner with a third party to build an LNG plant near the mine to ensure a sustainable supply.

Lion One and meeco plan solar/diesel power solution at Tuvatu gold project in Fiji

Environmental, Mining services, Power supply for mines, Precious metals, , , , , , , , ,

Lion One Metals has partnered with Switzerland-based clean energy provider the meeco Group to build and install a hybrid solar/diesel power plant at the Tuvatu gold project, in Fiji.

As part of this agreement, Lion One will be a 50% shareholder of a Special Project Vehicle (SPV) through an agreed buy-in structure.

Lion One will use meeco’s 7 MW peak “sun2live” solar power generation system, coupled with diesel generators, to generate up to 11 MW peak power production providing a continuous 24-hour source of power for the Tuvatu gold mine and processing plant. The installation will be built on 4.1 ha of unused land 3.5 km from the project and 17 km from the Nadi International Airport.

The new eco-friendly solar power system will have an estimated annual energy production of approximately 10.31 GWh, displacing more than 6,000 t/y of CO2 emissions, according to Lion One.

Lion One Managing Director, Stephen Mann, said: “meeco has a solid track record of installing and operating solar hybrid power plants worldwide. This hybrid system will not only reduce our carbon footprint, but will enable Lion One to meet our power capacity requirements while significantly reducing fuel consumption and operating costs for the Tuvatu gold project.”

Tuvatu is the largest undeveloped gold project in Fiji and one of highest-grade gold projects anywhere in the world, according to Lion One, with the company focused on building production of 100,000 oz/y over 10 years.

The process facility is designed with a nominal capacity of 219,000 t/y for a nominal design rate of 600 t/d based on an overall availability of 91% with a life of mine average feed grade of 11.3 g/t Au.