Tag Archives: engines

Volvo expands R100 rigid hauler market reach with Stage V/Tier 4 Final engine

Volvo CE says it has expanded the distribution of its 95 t (105 ton) R100 rigid hauler with the addition of an EU Stage V/US Tier 4 Final certified engine.

The Volvo R100 was originally launched in 2018 under the brand name R100E, but the new engine addition allows the truck to enter the strictest emissions regulated markets, opening up worldwide distribution, the company says.

“With a size and capacity that makes it the largest hauler in the company’s line-up, the R100 rigid hauler promises to drive down operating costs for customers by boosting productivity, fuel efficiency, operator comfort and uptime,” it added.

Power comes courtesy of a premium 783 kW Stage V/Tier 4 Final engine, with a combined drivetrain that provides high torque capabilities, unparalleled pulling functionality and class-leading rim pull for optimum performance, Volvo CE says. Drivetrain performance is supplied by the Volvo Dynamic Shift Control, which automatically installs optimum gear selection, speed and torque for improved fuel efficiency.

The truck features a 60.4 cu.m capacity dual-sloped body for improved load retention and minimal load shift, with the load profile policy enabling the operator to meet a consistent average target payload. The body-tipping fast cycle time, meanwhile, ensures all-round efficiency, the company says.

The Stage V/Tier 4 Final R100 includes a selectable Economy shifting mode for lighter working applications or high-speed applications and an auto-idle engine shutdown feature with adaptable timing that cuts unnecessary engine idling to reduce engine wear and operating costs.

Volvo says it has built on the high capacity and hauling performance of its rigid hauler with intelligent monitoring systems, with the On-Board Weighing option ensuring the machine moves the maximum safe payload, for cost-effective production.

The R100 is available with CareTrack – Volvo’s telematics system – to remotely monitor operational data, including fuel consumption, machine use, idling reports and GPS position.

Additionall, Volvo Site Simulation helps to define the most profitable fleet of equipment, site configuration and project results based on customer needs.

“By using the simulation, customers and dealers can work together to put an equipment plan in place before a project begins,” the company explains.

Swedish Stirling powers up South Africa ferrochrome industry advances

Swedish Stirling AB’s container-based energy recycling solution is taking off in South Africa’s ferrochrome sector, with two of the largest producers on board with the technology.

Based close to Gothenburg, Swedish Stirling Group is a clean tech company with a mission to scale up the conversion of thermal energy to electricity.

It is the company’s latest product – the PWR BLOK 400-F – that is finding favour in South Africa. This is a unique proprietary solution that uses Swedish Stirling’s Stirling engines for recovering energy from industrial residual and flare gases and converting them to 100% carbon-neutral electricity at a high rate of efficiency, according to the company.

The PWR BLOK 400-F contains 14 Stirling engines and delivers a net output of 400 kW.

Citing an independent certification, Swedish Stirling says the PWR BLOK is the cheapest way to generate electricity that exists today, yielding greater CO2 savings per Euro invested than any other type of energy.

Ferrochrome is renowned for being an energy-intensive process and load shedding is a common practice in power-constrained South Africa, hence the reason why it has been one of the frontrunners in adopting this technology.

Swedish Stirling explained: “Many industrial applications produce by-products in the form of gases (residual gas) that are currently burned without harnessing its energy content. Several solutions have been tried to recycle the energy in the gases.

“In the ferrochrome industry in South Africa, producers have tried to recover the energy using internal combustion engines, gas and steam turbines, but all solutions have failed. The reason is usually that the gas is of such uneven quality that most engines with internal combustion don’t work, or the technical solutions are extremely costly.

“The Stirling engine, on the other hand, is, due to its external combustion, almost insensitive to the type of gas that is burned or the quality of the gas in question. Therefore, it is now possible to start converting these residual gases into climate-smart electricity with PWR BLOK.”

And, this is exactly what is happening.

After installing a test PWR BLOK at Afarak Mogale’s smelter in South Africa over a year ago, the company has sealed contracts with Glencore and Samancor.

In the recent March quarter results, Swedish Stirling CEO, Gunnar Larsson, said: “Together, these (companies’ output) account for over 90% of the entire market in the country. This gives us a solid base for a wider-scale roll-out of the PWR BLOK in South Africa in the coming years.”

The agreement with Glencore will see it install and deliver up to 25 PWR BLOKs, generating 9.9 MW, to the Lydenburg smelter, while Samancor has signed up for a pilot facility with one PWR BLOK unit at the TC Smelter facility.

The company also, earlier this year, arranged a tour of the Mogale smelter for interested parties to spur further enquiries.

While the spread of COVID-19 has somewhat affected the company hitting its deadlines for these projects, it made progress with the Samancor delivery early last month, confirming that, after spending a number of weeks on a ship in Durban Harbour during the COVID-19 lockdown in South Africa, a PWR BLOK 2 unit was unloaded for transport to Samancor’s TC Smelter (pictured).

The company still hopes to install and commission the facility at TC Smelter during the June quarter as planned.

The agreement with Glencore’s Lydenburg smelter, meanwhile, could see carbon dioxide emissions from the smelter reduce by more than 80,000 t/y, due to the reduced need for purchased electricity, Swedish Stirling previously said.

Sandvik trialling Stage V engine technology at Boliden’s Tara mine

Sandvik is continuing its sustainability drive, announcing that it is trialling its first Stage V compliant underground truck at the Boliden-owned Tara zinc mine in Ireland.

The company, in December 2019, launched its first Stage V compliant underground LHDs for hard-rock mining applications following extensive testing. Back then, it said its newest intelligent loaders, the Sandvik LH517i and Sandvik LH621i, would receive the Stage V treatment in early 2020.

Now, Sandvik’s flagship truck, the TH663i, equipped with brand new Stage V Volvo Penta engine technology, is undergoing an extensive field trial period at Tara, allowing the company to obtain first-hand customer feedback on its technical and operational performance. Sandvik said this was “an integral part of Sandvik’s way of working and customer-focused mindset”.

The Stage V engine in the 63 t truck is expected to deliver lower emissions, contributing to reduced mine ventilation rates.

“Designed to fit seamlessly together with the truck and to perform specifically in underground use, the engine system includes built-in fire prevention solutions, increased wiring protection with shrink mesh wiring harness and electric hardware that is specifically designed for demanding conditions, with corrosion, heat and water resistance,” it said. “The new Stage V, requiring ultra-low sulphur fuel and low-ash engine oil to operate, will be an optional engine for the TH663i.”

To reduce particle emissions in the lower Stages/Tiers, standard engines on both the TH663i and TH551i trucks can be equipped with a diesel particulate filter (DPF), according to Sandvik. The company explained: “Based on studies conducted, the optional sintered metal DPF reduces particle mass by approximately 99%. From a reliability and maintenance viewpoint, the DPF is well protected but still designed for easy cleaning to reduce downtime and operating costs. The DPF is also available as retrofit kit.”

Pia Sundberg, Product Line Manager for Trucks at Sandvik Mining and Rock Technology, says thorough field tests are valuable to both the OEM and customer: “We want to allow enough time for sufficient testing of new technology, since it is of benefit to both sides.

“Possible hiccups that can often occur when developing something new are identified prior to the product being fully commercialised, which enables us to serve our customers better in the long run.

“Based on the feedback that we receive, we are still able to do some modifications if necessary and thereby make sure that the TH663i meets expectations when it is released to the market with the latest engine technology at a later stage. Of course, there is also some additional new technology on the test truck that we are testing at the same time.”

The TH663i also benefits from the recent improvements in Sandvik’s AutoMine® offering, as AutoMine for Trucks now enables autonomous truck haulage not only underground but also on the surface.

Sandvik said interesting glimpses into the company’s future truck offering have also been seen in Australia, where the Artisan Z50 battery truck from Sandvik carried out an extensive tour in early 2020 and gathered customer feedback for the new upcoming battery generation.

The company has also recently deployed a Z50 into Barrick Gold’s Turquoise Ridge underground gold mine, in Nevada.

MTU and ASI Mining to offer ‘integrated future-oriented autonomous solutions’

Rolls-Royce and Autonomous Solutions Incorporated (ASI) have signed a memorandum of understanding enabling Rolls-Royce to offer autonomous-compatible, Mobius-ready MTU engine solutions for equipment in a wide range of mining applications.

As part of the agreement, ASI Mining, a subsidiary of ASI, has agreed to ensure compatibility of MTU engines and ASI’s Mobius command and control software for autonomous vehicles.

With its brand MTU, Rolls-Royce business unit Power Systems is a leading provider of advanced power solutions for a wide variety of applications, including mining equipment. ASI Mining, meanwhile, is an industry leader in the development and sales of high-tech autonomous solutions for mining equipment and other machinery in a wide range of applications. The companies plan to leverage their experience to offer customers engine solutions that are compatible with ASI’s vehicle automation software to help optimise vehicle power performance and efficiency, thus enabling more environmentally friendly and safer mining operations, the two said.

Scott Woodruff, Global Director for Mining and Oil & Gas at Rolls-Royce Power Systems, said: “We are excited to shape the mining industry’s future together with ASI and further leverage our advanced MTU technologies. Together we will offer our customers integrated future-oriented autonomous solutions. This agreement may help mining operators save big on operational costs and at the same time, reduce their environmental footprint by cutting emissions.”

Drew Larsen, Director of Business Development for ASI Mining, said: “We are excited to start these discussions with Rolls-Royce Power Systems. This is another testament to the interoperability of Mobius and real value it adds to our mining customers.”

One potential benefit to customers of Rolls-Royce and ASI Mining may be the ability to retrofit the power system on existing haul trucks and convert them to autonomous operation, the companies said. The companies are interested in exploring the value customers would receive by modernising their trucks with more efficient MTU engines along with implementation of ASI’s industry-leading autonomous mining solutions. Customers would thus save on operating costs and further benefit from the increased performance of the autonomously optimised MTU engines, they said.

MTU says its diesel engines have been setting the standards for performance and fuel efficiency in mining applications around the globe for decades. “They reliably power vehicles for underground and surface mining, including loading vehicles such as excavators and wheel loaders, transport vehicles such as haul trucks or blasthole drilling rigs, and other mining machines – diesel-mechanic, diesel-electric or diesel-hydraulic,” it said. “For these applications, MTU engines provide high performance, reliability and availability as well as a maintenance-friendly construction. Long service intervals and an efficient use of fuel provide for exceptionally low operating costs of machines powered with MTU engines.”

ASI Mining’s Mobius, meanwhile, leverages advanced multi-vehicle command and control software to set up and manage a coordinated system of haul trucks. The Mobius Haulage Platform manages autonomous traffic, coordinates manned or unmanned vehicles and regulates the haul cycle in the most efficient way possible. By employing Mobius software, mines can improve utilisation, along with increase safety and productivity.

Sandvik and Volvo Penta collaborate on Stage V underground LHDs

Sandvik says it is readying the release of its first Stage V compliant underground loaders for hard-rock mining applications following extensive testing.

In early 2020, the company’s newest intelligent loaders, the Sandvik LH517i and Sandvik LH621i, will get the Stage V treatment. The Stage V Volvo Penta engines will be globally available as options, but require ultra-low sulphur fuel and low-ash engine oil to operate, Sandvik said.

The planned release follows more than 10,000 hours of LHD testing underground, on multiple customer sites in Europe, and with millions of hours of on-highway experience from Volvo. This has led to the new technology meeting customer expectations, equipment performance requirements and the most stringent emission regulations valid at the moment, according to Sandvik.

The base engine and selective catalytic reduction (SCR) purifier are proven Volvo technology, enhanced now with a ceramic diesel particle filter (DPF), according to Sandvik.

“As a result of the collaborative product development work, the engine – delivered by Volvo Penta – and Sandvik load and haul equipment work seamlessly together to maintain productivity and reliability in the most challenging environments,” Sandvik said.

The benefits of Stage V compliant loaders include reduced amounts of particles in the diesel exhaust – helping mines to improve air quality underground – and the ability to operate with up to 3% reduced fuel consumption, compared with previous stage engines.

Sandvik said: “Another key enabler for the equipment availability is passive regeneration of the diesel particulate filter; the soot accumulated in the filter is burned off during equipment normal operation, without the need for frequent stand still regeneration.”

A new feature in the Stage V engine is the modulating engine brake, which enables the operator to adjust the engine braking power, allowing for better control of vehicle speed downhill, while minimising brake and transmission overheating and brake wear. Both the modulating engine brake and the passive regeneration contribute to high uptime of the equipment.

Added benefits of the Stage V engines include high altitude operating capability – up to plus-3,500 m above sea level – and lower noise levels compared with previous Stage engines.

Petro-Canada Lubricants bolsters fleet protection with new engine oils

Petro-Canada Lubricants has expanded its TRAXON™ and DURON engine oil product lines with the launches of DURON™ Advanced 5W-30 and TRAXON Synthetic 75W-85.

The company, a HollyFrontier business, said the introduction of these new oils demonstrates its continued product innovation to help fleets meet new and emerging market trends.

DURON Advanced 5W-30 is a fully synthetic formulation designed to meet and exceed the requirements of the American Petroleum Institute’s (API) FA-4 standard. It has also been approved by major diesel engine original equipment manufacturers (OEMs) Cummins and Detroit Diesel.

This product line offers durable low viscosity, high performing synthetic and synthetic blend heavy duty diesel engine oils that are designed for emerging and future fuel-efficient engines, the company said. “These oils provide enhanced fuel economy, durability, engine protection and shear stability for the latest heavy-duty engines.”

TRAXON Synthetic 75W-85, meanwhile, expands the existing TRAXON Synthetic range providing fleet owners and operators with enhanced efficiency and long-lasting wear protection that can lead to longer equipment life and reduced unplanned downtime and associated maintenance costs.

“Offering year-round performance in the harshest environments, TRAXON Synthetic 75W-85 provides easier start-ups and improved cold weather shifting for manual transmissions, hypoid gears and rear axles,” the company said.

This low viscosity hypoid gear oil is designed to meet API Gear Lubricant Service GL-5 and API MT-1 Gear Lubricant standards and MACK GO-J standards for heavy-duty manual transmissions. It is also approved against the SAE J2360 Global Standard, the company said. The oil is suitable for use where Volvo 1273, 12 (97312) and Meritor 0-76-J specifications are required.

Alex Buczek, Category Manager of Heavy-Duty Engine and Driveline Oils, Petro-Canada Lubricants, said the new oils were specifically formulated to exceed industry requirements and offer improved performance and protection for fleets.

He added: “Our entire high performance, heavy-duty product line is designed with one purpose – to protect your bottom line. Our products help to make fleet equipment longer-lasting and more reliable; therefore operations can be more productive and profitable.”

Wärtsilä provides more engine technology applications with Modular Block

Wärtsilä says its newly launched Modular Block is a reliable and efficient solution for sustainable power generation, with fast delivery and installation.

The power plant solution is a pre-fabricated, modularly configured, and expandable enclosure for Wärtsilä medium-speed 34SG gas engine generators. Aside from the gas engine generator, the Wärtsilä Modular Block concept’s enclosure incorporates engine-specific auxiliary units, enabling a reduction in on-site installation time from “several months to a few weeks”, depending on the full scope of supply, Wärtsilä said.

“The concept thus makes Wärtsilä’s advanced medium-speed engine technology available for applications where it would not otherwise be viable with a conventional custom designed permanent building,” the company said, while adding that medium-speed engine technology has inherently higher efficiency and lower lifecycle costs than containerised high-speed engines or gas turbine solutions.

Wärtsilä says it can offer the Wärtsilä Modular Block as a full engineering, procurement and construction project, with the solution expandable to accommodate increased energy demand and to respond to fast-growing customer business needs. The concept also enables dismantling and relocation, meaning it offers new business models, such as power as a service or rentals.

On top of this, the Wärtsilä Modular Block is easy to integrate with renewable energy and storage systems, according to the company. “It is ideal for providing grid stability and balancing when integrating renewable energy sources with intermittent production.”

The flexibility of the concept enables timely expansion with minimal front-end investments, or relocation to accommodate changing power generating requirements, Wärtsilä said.

“This, combined with the high efficiency of the power generation asset, the minimised on-site installation time, and its configurability with external systems, makes the Wärtsilä Modular Block an excellent solution for many power generation enterprises,” the company said. “It can be a perfect fit for industrial customers or utilities, and for independent power producers associated with them.”

Antti Kämi, Vice President, Engine Power Plants, Wärtsilä Energy Business, said the Wärtsilä Modular Block takes the company’s experience and know-how in prefabricated modular power plants to the “next level, combining modularity and ease of use with superior medium-speed engine performance”.

Kämi added: “Modular Block, being a cost-effective solution that is configurable to different needs, scalable and re-deployable, brings fast and reliable power wherever needed.”

Wärtsilä introduced the Wärtsilä Modular Block at this week’s Africa Energy Forum, being held at the Lisbon Congress Centre, Portugal.

DEUTZ to supply SANY with China emission-compliant engines

DEUTZ has entered a joint venture agreement with SANY that will see the Germany-based company take over production of the China construction equipment manufacturer’s current engine range.

DEUTZ says it will be investing a mid-double digit million euro amount in the new joint venture and will hold a majority share of 51%. The closing of the transaction is expected by the end of the year. This agreement follows a memorandum of understanding the two companies signed in December last year (pictured).

The JV is aimed at supplying SANY with around 75,000 new engines in 2022, all of which will comply with the China IV emissions standard for off-road applications and China 6 for on-road applications, DEUTZ said.

“In addition to the successful conclusion of the joint venture deal with SANY, other elements of the international growth strategy are also going to plan in China,” DEUTZ said.

These include the strategic alliance with BEINEI to carry out production locally, with the DEUTZ management team overseeing the manufacture of about 20,000 engines for the Asia market in 2022 at a new factory in Tianjin, China. The ramp-up is set for 2020, when around 2,000 to 3,000 engines are to be produced, DEUTZ said.

“Further progress has also been achieved in the partnership between DEUTZ and FAR EAST HORIZON to expand the local service business,” DEUTZ said. “With more than 80 branches, FAR EAST HORIZON is the largest player in China’s construction equipment rental business and the ideal partner to meet the growing demand for innovative engines. DEUTZ customers will soon be able to benefit from digital services such as a shared online shop.”

DEUTZ CEO, Dr Frank Hiller, said: “The joint venture agreement marks an important milestone in the implementation of our new China strategy. We are now ideally positioned to take advantage of the rapid growth in the world’s largest individual market for engines.

“The alliances with our local partners will enable us to significantly increase our local presence for engines and we now have access to an attractive production network that will enable us to efficiently meet customer demand in the region. We can also tap into an extensive service network that we will systematically enhance with digital solutions. In an initial stage, we aim to achieve revenue of around €500 million ($550 million) by 2022.”

DEUTZ said the Chinese engines market has grown steadily in recent years and the uptrend is set to continue for some years to come. “Growth of up to 5% is forecast in China’s construction equipment application segment in 2019, while in material handling it is set to be up to 10%.”

Cummins powers up for the future of 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.

Bell ADTs benefitting from EU Stage V MTU Engines from Rolls-Royce

Bell Equipment, the articulated dump truck (ADT) specialist, recently received the first six Series 1000 – 1500 MTU engines from Rolls-Royce that meet the new EU Stage V emission standard, the engine specialist said.

The engines cover a power range from 170-430 kW.

The order had been preceded by a test phase of several years under the most adverse operating conditions in order to ensure the trucks would be guaranteed a reliable, cost-effective upgrade, according to Rolls-Royce. To this end, MTU’s off-road engine series were optimised to comply with the emission standard and a new exhaust aftertreatment system introduced.

In preparation for the more stringent emission requirements, Rolls-Royce had made two Stage V prototypes available to Bell for field trials in 2016 – a 260 kW MTU 6R 1000 engine and a 430 kW 6R 1500 were successfully tested in the hot, dusty climate of South Africa and for the tough conditions encountered at extreme altitudes of up to 3,000 m.

Bell and Rolls-Royce with the MTU brand have been working together closely since the 1990s, with Rolls-Royce not only the supplier of more than 1,000 MTU engines a year, but also the technology partner in all emission-related design and construction decisions – including the upgrading of the ADTs.

Stefan Rudert, Head of Sales and Application Engineering for Construction & Agriculture at MTU, said: “During the field trials, we accumulated an enormous amount of experience that goes way beyond any simulation on a test bench, since the real-life interplay between the engine and the vehicle affects the behaviour. Data obtained during the field tests, which we collected from sensors mounted on the engines was subsequently used in the configuration of the components.”

The new Stage V engines, which Bell will successively upgrade to, besides MTU’s current SCR exhaust technology, also include a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF), with all components installed in a compact one-box solution behind the driver’s cab, according to the company.

“Another positive aspect of the new emissions technology is that it reduces fuel consumption,” the company said. “To prepare for the upgrade to the new emission regulation, Rolls-Royce had around 100 MTU engines undergoing trials with various vehicle manufacturers.

“In total, over 110,000 operating hours were accumulated as a result, with individual engines running non-stop for more than 4,000 hours. Since the trials had started at an early stage, the MTU engines were certified in accordance with the EU Stage V regulations by mid-2018, marketable and ready for series production.”