Tag Archives: hydrogen

Perkins premieres new off-highway engine, reveals future fuel-agnostic plans

Environmental, Mining equipment, Mining events, Mining services, Power supply for mines, Sustainable mining, , , , , , , , , , , , ,

Perkins says it is addressing evolving industry demands for improved fuel efficiency and performance with a “next-generation” 13-litre diesel engine suitable for off-road applications.

Available in 2026, the Perkins® 2600 Series engine platform is designed for demanding requirements, as well as the realities of moving towards a lower-carbon future.

Perkins says the new 2600 Series achieves best-in-class power density, torque and fuel efficiency for heavy duty off-highway applications, with applications in mining, including excavators, dozers, drills, trucks, feeders, screens and pumps, among others.

It comes with eight power ratings from 340 kW to 515 kW, offering up to 3,200 Nm of peak torque. Industrial open power units configured with engine-mounted aftertreatment and cooling packs will also be available from the factory to reduce installation and validation costs for OEMs, the company said.

Perkins will offer 2600 Series engines configured to meet the emissions standards of higher regulated countries, such as EU Stage V, U.S. EPA Tier 4 Final, China Non-road IV, Korea Stage V, and Japan 2014, as well as versions for lesser regulated countries. The engines are compatible with renewable liquid fuels such as 100% hydrotreated vegetable oils (HVO), B100 distilled Biodiesel and up to B100 fatty acid methyl ester standard biodiesel.

Additionally, the platform’s core architecture supports the future development of spark-ignited natural-gas and hydrogen fuel capabilities, according to the company.

To date, engineers have completed more than 20,000 hours of design validation on the 13-litre engine platform, with early OEM pilots available in 2025 and commercial production scheduled to begin in 2026.

Speaking at a press event held in London yesterday, Product Marketing Manager, Allen Chen, said prototypes were already out in the field in construction, agriculture and material handling applications, some of which were testing the highest power category.

He also said the new design piggybacked off the development of the smaller 904 Series engine, and was engineered for “tomorrow” with options for a drop-in exhaust gas recirculation system should future regulations require further emission reductions.

Hybrid power options – diesel-electric, among them – were also front of mind when designing this engine, Chen added.

Perkins says it is continuously developing and optimising a large, fast-growing portfolio of advanced power product and service solutions designed to help customers manage the energy transition to a more sustainable, lower-carbon future, including:

  • 48-, 300- and 600-volt lithium-ion battery solutions with modular designs and factory-installed telematics that Perkins is developing to optimise performance and packaging in numerous next-generation off-highway applications;
  • EU Stage V and U.S. EPA Tier 4 Final industrial diesel engines and industrial open power units that are already available to help OEMs reduce greenhouse gas emissions from their machines;
  • A full range of engines that today, without modification, can use a wide range of lower-carbon intensity drop-in fuels such as HVO and biodiesel;
  • Highly configurable integrated, end-to-end diesel-electric hybrid powertrains, suitable for a wide range of off-highway applications;
  • Connectivity solutions with hardware reading important engine data, displayed to the customer as timely insights; and
  • Aftermarket capabilities promoting sustainability through improved fuel efficiency and prolonged machine life cycles, such as Perkins Hypercare packages and overhaul kits to full replacement engine solutions.
Perkins says it has highly configurable integrated, end-to-end diesel-electric hybrid powertrains, suitable for a wide range of off-highway applications

At that same press event, Paul Moore, Head of Powertrain System Integration Engineering – Industrial Power Systems division, revealed details of “Project Coeus”, which has been established to come up with a “compact drop-in solution for flexible low carbon intensity power”. Such a solution would leverage hardware and software that allows the use of alternative fuels – ethanol, methanol, bio-methane and hydrogen – to be used within the Perkins engine portfolio.

Moore said a solution could be demonstrated in a machine in three years’ time that allowed such agnostic fuel supply options.

Jaz Gill, Vice President of Global Sales, Marketing, Service and Parts, said of the 2600 Series: “As the off-highway industry advances toward a lower-carbon future, equipment manufacturers still face expectations for long-term productivity and reliability in the world’s most demanding work environments. The new Perkins 2600 Series engine platform demonstrates how we’re leveraging our experience, intelligence and commitment to help OEMs navigate the energy transition with power solutions that deliver exceptional performance on the work site.”

The Perkins 2600 Series showcases the company’s commitment to innovations that support the success of customers by challenging traditional assumptions – which was evidenced by the 82 patents granted to date across the entire engine platform, the company said.

The engines are designed to perform at altitudes of up to 12,000 ft (3,658 m), and in extreme ambient temperatures as high as 60°C and as low as minus 40°C with aids.

The engine supports quality, reliability and easier maintenance through numerous design enhancements, including the integration of components as well as a reduction in the number of leak joints by more than 45%, the company says. Together, the upgrades result in lower fluids consumption and extended oil and fuel filter service intervals as long as 1,000 hours, reducing operating costs and downtime.

Perkins said: “2600 Series engines will offer telematics solutions enabling OEMs to collect, analyse and integrate key engine performance data within a connected intelligent platform. By modularising and eliminating components, its architecture is space-protected to accommodate configuration adjustments anticipated for future tiers of emission standards in the US and EU without relocating customer connection points. All eight power ratings for higher regulated markets will be available on a common core engine, enabling OEMs to reduce their inventory and integration costs.”

It added: “The combination of the all-new rear gear train, stiffer core architecture, and common rail fuel system reduces noise by up to 3 dB when compared with Perkins current 13-, 15- and single-turbo 18-litre engines.”

The launch came at the same time Perkins unveiled a new global strategy to advance sustainable power with a brand refresh – a move, it said, better reflects its commitment to helping customers confidently challenge conventional wisdom and explore new ways to achieve their power and climate-related goals.

A subsidiary of Caterpillar Inc. for over 25 years, Perkins says it pioneered diesel engine power in the 1930s and has continuously evolved to help customers navigate technological change and solve complex challenges. Since its founding, the brand has manufactured over 22 million engines – with more than 4.5 million in use in over 5,000 different applications today.

The new Perkins brand strategy communicates a clear promise – “delivering smarter solutions to advance sustainable power” – and a renewed sense of purpose rooted in helping customers build and power a better, more sustainable world, it said.

Rio Tinto, Sumitomo Corp to cut alumina refinery emissions with Gladstone hydrogen plant

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Rio Tinto and Sumitomo Corporation are to build a first-of-a-kind hydrogen plant in Gladstone, Australia, as part of a A$111.1 million ($74.6 million) program aimed at lowering carbon emissions from the alumina refining process.

The Yarwun Hydrogen Calcination Pilot Demonstration Program received the green light after a A$32.1 million co-funding boost from the federal government’s Australian Renewable Energy Agency (ARENA).

The program is aimed at demonstrating the viability of using hydrogen in the calcination process, where hydrated alumina is heated to temperatures of up to 1,000°C.

It involves construction of a hydrogen plant at the refinery and the retrofit of refinery processing equipment. If successful, the program could pave the way for adoption of the technology at scale globally, Rio says.

Rio Tinto Aluminium Pacific Operations Managing Director, Armando Torres, said: “This pilot plant is an important step in testing whether hydrogen can replace natural gas in Queensland alumina refineries. At Rio Tinto we have put the energy transition at the heart of our business strategy, and this is one of the ways we’re working towards decarbonising our operations.

“We are proud to be developing this new technology here in Gladstone, in partnership with Sumitomo Corporation, and with support from ARENA.”

The project will consist of construction of a 2.5 MW on-site electrolyser to supply hydrogen to the Yarwun refinery and a retrofit of one of Yarwun’s four calciners so it can operate at times with a hydrogen burner.

The trial is expected to produce the equivalent of about 6,000 t/y of alumina while reducing Yarwun’s carbon dioxide emissions by about 3,000 t/y.

Converting the entire plant to green hydrogen could reduce emissions by 500,000 t/y, Rio estimates, the equivalent of taking about 109,000 internal combustion engine cars off the road.

Construction will start in 2024. The hydrogen plant and calciner are expected to be in operation by 2025.

Sumitomo Corporation will own and operate the electrolyser at Yarwun site and supply the hydrogen to Rio Tinto directly. The electrolyser will have a production capacity of more than 250 t/y of hydrogen.

Sumitomo Corporation Energy Innovation Initiative Director, Seiji Kitajima, said: “We are excited to be delivering this hydrogen project together with Rio Tinto as our long-term partner with the support of ARENA.

“Demonstrating real-world applications of hydrogen in industrial settings with motivated partners is essential to reducing carbon emissions and working toward our company’s vision of achieving carbon neutrality by 2050. Through this demonstration, Sumitomo Corporation aims to venture into the commercialisation project to contribute to Rio Tinto’s decarbonisation.

“Sumitomo Corporation is proud to be working on yet another hydrogen project in Australia and contributing to Australia’s own emission reductions goals.”

The pilot plant follows the success of a A$1.2 million feasibility study co-funded by Rio Tinto and ARENA that was announced in 2021.

Rio Tinto says it is committed to achieving net-zero emissions by 2050 and has targets to reduce Scope 1 & 2 emissions by 50% by 2030 from 2018 levels.

BHP and Hatch commence design study for an electric smelting furnace pilot

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BHP and global engineering, project management and professional services firm, Hatch, have signed an agreement to design an electric smelting furnace pilot (ESF) plant in support of a decision to construct this facility in Australia.

The facility will aim to demonstrate a pathway to lower carbon dioxide (CO2) intensity in steel production using iron ore from BHP’s Pilbara mines for BHP’s steelmaking customer, BHP says.

The small-scale demonstration plant would be used to collaborate with steel producers and technology providers to generate and share learnings with the aim of accelerating scale up of ESF plant designs.

The pilot facility would be intended to test and optimise production of iron from the ESF, a new type of furnace that is being developed by leading steel producers and technology companies targeting low CO2 emission-intensity steel. The ESF is capable of producing steel from iron ore using renewable electricity and hydrogen replacing coking coal, when combined with a direct reduced iron (DRI) step. Estimates show that reductions of more than 80% in CO2 emission intensity are potentially achievable processing Pilbara iron ores through a DRI-ESF pathway, compared with the current industry average for the conventional blast furnace steel route, BHP says.

The ESF allows for greater flexibility in input raw materials, addressing a key barrier to wider adoption of other lower CO2 emissions production routes, such as use of electric arc furnaces which are designed for scrap steel and high grade DRI only. The ESF also has the potential to be integrated into a steel plant’s existing downstream production units.

The pilot facility will enable deeper and more accurate insights into the performance of this technology for converting iron ores into molten iron and steel. Planned test programs will help de-risk further investment in commercial scale projects, thereby complementing development plans of BHP’s steel customers. This scale-up approach has been utilised by other industry demonstrations such as Sweden’s HYBRIT project, BHP added.

BHP and Hatch will assess several locations in Australia for the proposed facility based on supporting infrastructure, technology skills and the availability of local partnerships to build and operate the facility.

BHP’s Chief Commercial Officer, Vandita Pant, said: “We see the ESF process as a critical breakthrough in significantly reducing the carbon emissions intensity of steel production and one that provides an opportunity for iron ore from our Pilbara mines. The steel industry has identified the ESF as a viable option to use a wider range of raw materials and steel companies globally are looking to build commercial-scale ESF plants as part of their CO2 emission reduction roadmaps.”

BHP’s Group Sales and Marketing Officer, Michiel Hovers, said: “Hatch is a key partner in carbon emissions reduction initiatives across the world. We are pleased that we can collaborate with Hatch, alongside BHP’s existing customer and research partnerships, to further progress the development of pathways towards a lower GHG emission footprint for the steelmaking industry. The ESF technology is very exciting and potentially very relevant for reducing the carbon emissions intensity of steel production and provides new and exciting opportunities for our Pilbara iron ore and our customers.

“BHP and Hatch have collaborated on steel technology and design for reducing GHG emissions from over several years, including the ESF and in collaboration with steel producers, and this project is a natural progression in our partnership.”

Hatch’s Managing Director for Bulk Metals, Joe Petrolito, said: “Hatch is excited to collaborate with BHP on this forward-looking initiative and is honored to contribute to the efforts of an industry leader who is dedicated to driving tangible progress. This project marks a significant milestone in the pursuit of decarbonisation within a challenging sector that underpins global infrastructure and progress.”

Primetals, Mitsubishi, Fortescue and voestalpine team up to tackle net-zero emission ironmaking

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Primetals Technologies, Mitsubishi Corporation, Fortescue and voestalpine have signed a Memorandum of Understanding (MoU) aimed at designing and engineering an industrial-scale prototype plant with a new process for net-zero-emission ironmaking at the voestalpine site in Linz, Austria.

The collaboration will also investigate the implementation and operation of the plant, the companies say.

The new ironmaking process will be based on Primetals Technologies’ HYFOR and Smelter solutions. HYFOR is, according to Primetals, the world’s first direct reduction process for iron ore fines that will not require any agglomeration steps, like sintering or pelletising. A pilot plant has been in operation since the end of 2021, and Primetals has run numerous successful test campaigns over the last year including successful trials on Fortescue’s Pilbara iron ore products.

The new Smelter technology from Primetals Technologies is a furnace powered by electrical energy. It is used for melting and final reduction of direct reduced iron (DRI) based on lower-grade iron ore. In that way, it produces alternative green hot metal for the steelmaking plant.

The project planning phase will be used to design an industrial-scale prototype plant with a capacity of between 3-5 t/h of ‘green’ hot metal. It is the first solution to link a hydrogen-based direct reduction plant for iron ore fines with a smelter, Primetals says.

The main goal of the project planning phase is to develop the basis for decision to realise a prototype plant capable of continuous operation, and then to gain the know-how needed for the next step: a commercial full-scale plant. Another target is to investigate the use of various types of iron ores to produce DRI, hot briquetted iron and hot metal and, as a next step, draw conclusions about the individual process steps as well as different combinations of them.

The hydrogen used in the new plant will mainly come from Verbund, voestalpine’s and Austria’s leading renewable energy producer, who operates a proton exchange membrane electrolyser named H2Future. Located in Linz, this plant has a capacity of over 6 MW, and is still the world’s largest of its kind used at a steel plant. The H2Future plant will be upgraded to allow for the compression and storage of hydrogen gas before use in the combined HYFOR and Smelter plant.

Hubert Zajicek, Member of the Management Board of voestalpine AG and Head of the Steel Division, said: “voestalpine has a clear plan to decarbonise steel production with the greentec steel program. An important first step is the incremental shift from the blast furnace route to a hybrid-electric steel pathway from 2027.

“Over the long term, our mission is carbon-neutral steel production using green hydrogen, for which we are already undertaking intensive research into promising breakthrough technologies. With the joint project with Primetals Technologies and Fortescue, we are taking another new path towards achieving the goal of CO2-neutral steel production by 2050.”

Fortescue’s main responsibility in the new project is to provide knowledge about iron ore quality and preparation. In addition, Fortescue will supply various iron ores for the new plant.

Fortescue Future Industries (FFI) CEO, Mark Hutchinson, said the partnership was the perfect alignment of the company’s mining and renewable energy goals.

Metso Outotec to develop hydrogen-based DRI pilot plant in Germany

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Metso Outotec says it will convert its existing 700 mm circulating fluidised bed (CFB) pilot plant in Frankfurt, Germany, for hydrogen-based direct reduction of fine ore as it looks to further drive down carbon emissions associated with the iron-making part of steel production.

The company will apply its Planet Positive Circored™ technology as part of this process, with the pilot plant able able to be used for the reduction of high-grade iron fines concentrate and to confirm the design basis for an industrial-scale Circored plant.

Commissioning of the plant is expected to take place by December 2023.

Parizat Pandey, Director, Direct Reduced Iron (DRI) at Metso Outotec, said: “The investment enables us to pilot the reduction of low-grade iron concentrate fines in larger quantities than what we do today, and, subsequently, perform downstream fines DRI electric smelting tests for hot metal production.

“The Circored processing route used in the process offers the lowest possible carbon footprint in the iron-making segment of an integrated steel plant.”

Once operational, the 700 mm pilot plant will be able to continuously produce 150-200 kg/h of direct reduced iron, using 100% hydrogen as the sole reducing agent, Metso Outotec claims. The pilot plant will have an integrated pre-heating and reduction section, followed by a gas cleaning and recirculation facility.

The investment includes installation of electric heaters in the process, making it an almost zero-carbon-emission plant, according to the company. Further, the data obtained from the use of electric heaters will be used to scale up the design of industrial heaters capable to running on renewable energy.

The Circored process is based on the fluidised bed knowledge and experience developed and applied by Metso Outotec over decades in hundreds of plants for different applications. The process applies a two-stage reactor configuration with a CFB followed by a bubbling fluidised bed downstream. The typical plant capacity is 1.25 Mt/y per line. Two or more lines can be combined using joint facilities and utility areas. In standalone plants, the produced DRI is briquetted to hot briquetted iron to enable further handling and safe transport.

If a Circored plant is integrated into an existing steelmaking facility, energy efficiency can be further increased by direct hot feeding of the DRI to an electric arc furnace, according to Metso Outotec.

Anglo American invests $200 million into new nuGen-focused First Mode vehicle

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Anglo American’s ambitious plans to roll-out its nuGen™ Zero Emissions Haulage Solution (ZEHS) have been given a boost with the announcement that it has signed a binding agreement with First Mode Holding to combine to the two entities.

Such a deal was mooted back in June when Anglo American confirmed it was in exclusive negotiations with First Mode – and had agreed non-binding terms – to combine the nuGen ZEHS with the specialist engineering technology company.

The two companies’ collaborative efforts led to the launch of the prototype nuGen ZEHS hydrogen-powered mine haul truck at Anglo American’s Mogalakwena PGMs mine in South Africa on May 6, 2022. This month the truck reached a significant milestone when it completed initial commissioning and was introduced into the mine’s commercial fleet operations, including pit and crusher activities, according to First Mode.

The latest agreement will see the mining company invest $200 million into a combined business to help fund the ongoing development of ZEHS which, upon completion of the transaction, values the business in the order of $1.5 billion and results in Anglo American owning a majority shareholding in First Mode.

Upon closing of the transaction, expected in January 2023, Anglo American will enter into a supply agreement with First Mode to decarbonise its global fleet of ultra-class mine haul trucks, of which approximately 400 are currently in operation, in support of Anglo American achieving its 2040 target for carbon-neutral operations.

The roll-out across Anglo American’s haul truck fleet over the next circa-15 years is subject to the completion of agreed and committed studies across seven mine sites, certain performance and cost criteria, and relevant regulatory, corporate and shareholder approvals, the mining company said. The supply agreement also includes the appropriate provision of critical supporting infrastructure such as refuelling, recharging and facilitation of hydrogen production.

Anglo American says it also recognises its role in supporting broader decarbonisation objectives outside its own business and that the technologies and capabilities it develops as part of the nuGen project present opportunities in other industries that rely on heavy duty forms of transport, such as rail.

In addition to accelerating the development and commercialisation of the ZEHS technology, the new combined business will allow strategic third parties to co-invest alongside Anglo American and First Mode, offering the opportunity to accelerate their own decarbonisation and participate in the potential offered by the clean ZEHS technology, the company added.

“The new combined business retains the First Mode name and will prioritise developing nuGen ZEHS, building on three years of extensive development by Anglo American and First Mode,” the company concluded.

In a separate press release from First Mode, it mentioned that current First Mode President and CEO, Chris Voorhees, will transition to the role of Chief Product & Technology Officer, overseeing the company’s global product and technology development out of Seattle. Julian Soles, Anglo American’s head of Technology Development, will take over as First Mode CEO and be based in First Mode’s new headquarters in London.

Voorhees said: “First Mode was founded in 2018 with the goal of building the barely possible. We have done just that and our mission is now to rapidly decarbonize heavy industry by dramatically reducing our customers’ greenhouse gas emissions. I can’t imagine a team better suited to this urgent challenge.”

Soles added: “The First Mode mission is much bigger than a single haul truck. Mining is how the world obtains the materials needed for the clean energy transition, and it is where the carbon footprint starts. This is where the First Mode solution begins; starting at the source, in mining, to replace diesel and accelerate the clean energy transition.”

Hybrid Systems Australia and Horizon Power open renewable hydrogen demo plant

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Hybrid Systems Australia, Pacific Energy’s integrated renewables subsidiary, has joined Horizon Power in officially opening Horizon Power’s renewable hydrogen demonstration plant.

The Australian-first project, which is being delivered in partnership by Horizon Power and Hybrid Systems Australia, will test the technological and commercial viability of renewable hydrogen as a baseload power source.

Hybrid Systems Australia was engaged to design, construct and commission the plant and worked closely with fellow Pacific Energy subsidiary, ENGV, to supply and install hydrogen equipment in the integrated system, including a 348 kW electrolyser, a specialised hydrogen compression and storage system and a 100 kW fuel cell.

The company also constructed a 704 kW solar farm to generate the renewable energy required to produce hydrogen.

In addition to providing valuable learnings for future applications of renewable hydrogen across the power generation sector, the system aims to demonstrate the efficiency of the hydrogen equipment such as the electrolyser and fuel cell, the ramp rate of hydrogen in response to a decline in solar generation, and the efficiency and storage capability of hydrogen fuel cells versus batteries.

Hybrid Systems Australia’s Executive Director, Mike Hall, said the project had proved ground-breaking, providing plenty of opportunities to further develop the company’s expertise and add value more broadly to the burgeoning sector.

“As an industry-first, this project has presented some really interesting opportunities for us to grow our capabilities in the green hydrogen project delivery space,” he said.

“It’s still a budding industry in Australia, so we really had to start at the beginning, from designing a system based on first principle thinking to navigating both existing and newly developing industry regulations and licensing designed for different applications. We’ve worked closely with Horizon Power and regulators to get the process right, and it’s been a very dynamic project, but we looked at any challenges as growth opportunities, and in doing so, we’ve been able to see things through fresh eyes.

“We’re looking forward to seeing the outcomes of Horizon Power’s Denham project and ongoing research and, furthermore, what it means for renewable hydrogen in utility-scale applications.”

The plant, which produced its first hydrogen in October, is expected to produce renewable energy equivalent to the average power demands of 100 households, or about 20% of Denham’s residential and business power needs, and will offset approximately 140,000 litres of diesel annually.

The project is a A$9.3 million ($6.2 million) investment, co-funded by Horizon Power, the Western Australian State Government and the Australian federal government. The Western Australia Government provided A$5.7 million of funding, with A$1 million through the Renewable Hydrogen Fund. The Australian Renewable Energy Agency (ARENA) provided A$2.6 million of funding through its Advancing Renewables Program.

Hybrid Systems Australia, a subsidiary of the QIC-owned Pacific Energy Group Holdings Pty Ltd, is currently commissioning Horizon Power’s renewable hydrogen demonstration plant, which is expected to be fully operational in early 2023.

FFI and IPL’s Gibson Island ‘green ammonia’ plans progress to engineering stage

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Fortescue Future Industries (FFI) and Incitec Pivot Limited (IPL) will progress planning for the conversion of IPL’s Gibson Island ammonia facility to run on green hydrogen to its final stages, electing to commence front end engineering design as well as executing a framework agreement to govern the project through to a final investment decision, Fortescue Metals Group says.

With studies having confirmed its feasibility, the proposed project could see the construction of a new circa-500 MW hydrogen electrolysis facility at the site to produce green hydrogen as well as the retrofitting of IPL’s existing ammonia manufacturing facility to run on the green hydrogen produced on-site.

IPL’s Gibson Island facility will cease traditional fertiliser manufacturing early in the new year. As part of IPL’s decarbonisation strategy and in line with FFI’s goals to help heavy industry decarbonise, the Brisbane ammonia manufacturing and port facility conversion would be a world-first, Fortescue claims.

The two companies said last year they were partnering on a project to conduct a feasibility study to convert the ammonia-production facility to run on green, renewable hydrogen.

IPL Managing Director and CEO, Jeanne Johns, said the company was pleased to create a pathway to a more sustainable future for the Gibson Island ammonia manufacturing facility after traditional fertiliser production ceases.

By virtue of running on green hydrogen, the facility could ultimately produce up to 400,000 t/y of green ammonia, which can be exported to international markets as well as used in fertiliser or to help decarbonise local industry through its potential use as a low-carbon fuel source for ports, airports and heavy transport.

Front end engineering design (FEED) is a critical phase in development and will firm up technical specifications and cost, underpin procurement, as well as mature the project to final investment decision (FID), targeted for 2023. The FEED phase is anticipated to cost around A$38 million ($24 million), with the federal government, through the Australian Renewable Energy Agency, contributing A$13.7 million.

FFI CEO, Mark Hutchison, said around 100 jobs would be supported across the project in the lead up to FID, with first production, subject to FID, expected around 2025.

“Progressing this project into this final assessment stage is an important milestone in what will be a world-first conversion of an existing facility to become an industrial-scale producer of green hydrogen and green ammonia,” Hutchinson said.

“This collaboration aims to put Queensland and Australia ahead of the pack – not only in terms of the scale of production and supply of green hydrogen and green ammonia, but also in terms of demonstrating to the world that projects like this are feasible and that Australia has the foresight, the commitment, and the know-how to invest in and deliver them.

“We’re so pleased to have the support of a partner in IPL who are as invested as we are in developing real-world solutions to reduce our reliance on fossil fuels, and equally appreciate the support of the federal government who are a key enabler of us progressing the project to its final development phase.”

Johns said the announcement was a significant step forward for sustainability with IPL and FFI leading the global charge.

“The potential conversion of Gibson Island to green ammonia shows our commitment to pursuing opportunities to help create a more sustainable world in the new and emerging opportunities stemming from green ammonia,” Johns said.

“We are very pleased to be able to partner with FFI on what would be a world-first project, and I extend my thanks for the partnership and support from both the federal and Queensland governments.”

The parties are also working with the Queensland Government to understand how the project could benefit local energy markets and support the delivery of the Queensland Government’s Energy and Jobs Plan and broader development objectives.

TNG enlists Metso Outotec’s H2-based Circored process for Mount Peake concentrate plans

Energy minerals, Metallurgy, Mineral project development, Mining equipment, Mining services, Steel and iron ore, Sustainable mining, , , , , , , , ,

TNG Limited, an Australia-based resources company, has awarded Metso Outotec a study looking at reducing Mount Peake Ti-V magnetite concentrate using Circored™ technology, which uses hydrogen as its only reductant source.

As part of the study, Metso Outotec will perform a techno-economic assessment to integrate Circored technology into TNG’s TIVAN® process that provides for the extraction of high-quality products from Ti-V magnetite orebodies.

Metso Outotec has been granted this assignment following positive test work performed for TNG, which confirmed the applicability of hydrogen-based reduction for Mount Peake Ti-V magnetite concentrate.

The test work program, which was a precursor to a more detailed commercial and technical evaluation, was a success, TNG says, delivering the following results:

  • Achieved iron metallisation targets across a range of testwork parameters;
  • Demonstrated the viability of processing Mount Peake titanomagnetite concentrate with Metso Outotec’s Circored technology; and
  • Generated samples for downstream validation testwork.

Now, Metso Outotec will further define the process flowsheet for the Mount Peake project and prepare a preliminary capital cost and operating cost (+/-30%) for a Circored Plant.

The use of hydrogen is a key part of the TNG’s medium-to-longer-term strategy to reduce its net carbon footprint from processing operations at the Mount Peake project.

TNG Managing Director & CEO, Paul Burton, said the Metso Outotec study also complements its existing partnership with SMS group, which TNG has a strategic partnership with, to investigate green hydrogen production at Mount Peake.

Located 235 km north of Alice Springs, in the Northern Territory of Australia, Mount Peake will be a long-life project producing a suite of high-quality, high-purity strategic products for global markets including vanadium pentoxide, titanium dioxide pigment and iron ore fines, accordiing to TNG. The project has received Major Project Status from the Australian Federal Government and the Northern Territory Government.

Circored, part of Metso Outotec’s Planet Positive portfolio, is a process that uses hydrogen as the sole reducing agent in the reduction of fine ores, enabling carbon neutrality for metal processing plants.

Shell on the future of fuel switching

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Mark Hannan, General Manager for Mining Decarbonisation at Shell, explores how mining operators can switch their fleets from diesel to low-carbon fuels as part of a wider transition to zero-carbon fuels.

The mining industry is in need of decarbonisation but delivering change at pace is a real challenge. There is huge pressure to achieve this when, it is estimated, 10% of the world’s energy-related greenhouse gas (GHG) emissions come from primary minerals and metals production, according to Nature Geoscience Magazine (2020).

For a mining company to achieve their decarbonisation goals, it is beneficial to maximise the benefits in the short term while providing greater flexibility for the long term. One such area that offers opportunities for this is fuel switching in mining fleets.

Decarbonisation drives the need for alternative fuels

No matter what stage a mining business has reached on its pathway to decarbonisation, it is important to review how its mobile assets impact the environment. McKinsey shows that between 40-50% of CO2 emissions in mining come from the diesel used for mobile assets.

Due to concerns around diesel fumes in confined spaces, the problem is largely being solved in underground sites – with some due to run entirely on battery-electric assets in the near term. In open-pit mines, where equipment is larger, emissions from diesel fuel are a challenge still to overcome, which is why fuel switching is essential to decarbonisation.

However, there are still many elements to consider when making the business case for alternative fuels. This includes the performance of alternative fuels in comparison with diesel, the capital investment needed to implement them and how widely available they are. That is before analysing the benefits of meeting emissions targets against the higher cost of using low-carbon fuels.

A net-zero future is coming, but it is not here yet

In the longer term, there are two diesel alternatives that will offer key routes to effective fuel switching: hydrogen and electricity.

Hydrogen is set to play a significant role in the decarbonisation of every industry – not least those featuring hard-to-abate sectors like mining. As well as reducing emissions in overall energy use across sites, hydrogen will provide a low-carbon alternative to diesel that also delivers higher energy density to drive the performance of mobile assets.

Government support for hydrogen power is growing rapidly and it is an area in which Shell is working closely with customers and original equipment manufacturers (OEMs) to drive innovation and deliver supply at scale. However, with hydrogen supply dependent on elements such as the availability and cost of technology, land, water, storage and transport, it is an alternative that will only start to present real impact from 2030 and beyond.

For off-highway equipment in mining, fleet electrification is often seen as a more relevant near-term solution. This is not surprising as electric power can not only contribute to reduced emissions but also help businesses shift away from their exposure to volatile diesel prices – potentially leading to a positive impact on total cost of ownership (TCO).

To help deliver on the mining industry’s longer-term aspirations for fleet electrification, Shell is developing a suite of modular end-to-end solutions for mining heavy-duty vehicles that decarbonises haul trucks while minimising the operational impact of electrification in a scalable, interoperable and sustainable way.

When looking to make the switch to electrification, mining companies must address the significant escalation in power demand that would come with full-scale electrification. Also, they will want to know the electricity is generated from renewable sources – helping them to reduce their Scope 1 and 2 emissions. Electrification powered by renewable energy will be a significant driver of change for mining sites, which is why Shell is working to overcome the barriers to increasing its renewable capacity – such as the need for upgrades to the grid and storage capabilities.

Low-carbon fuels offer an immediate next step for mining businesses

Hydrogen and electrification represent the future of fuel for mobility in mining. But, in the short term, there is another alternative that can act as a transition fuel and help lower emissions while businesses wait for hydrogen and electricity to become viable at scale: low-carbon fuels.

There are two types of low-carbon fuels relevant to mobility in mining:

  • Biodiesel – also known as Fatty Acid Methyl Ester (FAME); and
  • Renewable diesel – also known as Hydrotreated Vegetable Oil (HVO)

Though both are derived from organic biomass like waste vegetable oils and animal fats, there are differences in their chemical composition owing to a different manufacturing process that impact their use. For instance, biodiesel is the more affordable choice, yet most OEMs place a limit on the percentage it is possible to blend with conventional diesel due to quality concerns such as storage stability and performance in cold temperatures. Renewable diesel more closely resembles the composition of conventional diesel, meaning it can be blended in any ratio up to a concentration of 100%, but is more expensive due to the complexity in refinery processing. Crucially, both fuels offer a route to emissions reduction in mining – and a combination of the two is likely to be needed.

These low-carbon fuels offer a more immediate solution to the challenges of fleet decarbonisation in mining, without making costly investments in infrastructure. Not only can they be used in existing heavy-duty diesel engines, but, as long as they are in accordance with manufacturer advice, they also require no infrastructure investment. This makes them a more affordable short-term option that enables businesses to reduce emissions today while working to implement the ecosystem needed to transition to hydrogen and electricity tomorrow.

Overcoming the challenges of availability at scale

The merits of low-carbon fuels for a sites’ mobility needs might already be clear. After all, the technology is mature and it is easy to implement – certainly compared with hydrogen and electricity. However, there are still barriers to overcome before we see widespread adoption in the mining industry.

Availability and affordability are the two critical challenges. Despite its maturity, supply of low-carbon fuels is tight – especially given the remote regions that mining operations usually take place in. The need to comply with regional regulations on renewable fuels is also driving rising demand. For example, the EU Commission’s renewable energy directive has proposed increasing its target for renewable energy sources consumption by 2030 to 45% (up from its current goal of 32%).

Also, mining is not the only sector looking to alternative fuels to drive decarbonisation, meaning businesses will need to compete and trade with areas like commercial road transport to source low-carbon options. With more users needing access to alternative fuels, premiums for low-carbon fuels remain high. This can make low-carbon fuels less affordable and risks undermining any TCO improvements businesses can expect to realise from fuel switching.

It means that businesses are hesitant to act today as they wait for more capacity and greater competition to arrive – even though mining cannot afford to delay its emissions reduction efforts. That is why, at Shell, we are working to deliver additional capacity and competition. As well as investing in new production facilities (including a new biofuels facility in the Shell Energy and Chemicals Park Rotterdam, which will produce sustainable aviation fuel and renewable diesel made from waste in The Netherlands once it comes onstream), we are using our existing relationships with OEMs to help mining businesses get the most out of the low-carbon fuels they do have access to.

Collaboration will be critical to fuel switching success

Ultimately, if mining businesses are to meet their regulatory responsibilities while driving performance, they will need to unlock the opportunity that fuel switching provides. From low-carbon fuels to electrification to hydrogen, there is huge potential to reduce emissions while improving the TCO of mining mobility.

Successful fuel switching will require close collaboration with partners and suppliers to create a new fuel ecosystem by improving the availability and affordability of alternatives to conventional diesel. Only by working together will we deliver a new fuel future for mining, which is why Shell Mining is committed to supporting the industry on every step of its decarbonisation journey.

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