Tag Archives: mining engines

Rolls-Royce truck engine repower project lowers emissions at Los Bronces

Rolls-Royce Solutions and its Chile-based distributor Detroit Chile S.A. have helped lower emissions associated with Anglo American’s Los Bronces haulage operation thanks to a strategic engine repowering project on its 30-strong fleet of Komatsu 930E haul trucks.

The project for Los Bronces, a copper mine in Chile, originated with the mining company looking to comply with incoming emission guidelines for mine operations, as well as Anglo American’s own plans to make operations increasingly sustainable over the long term.

For the fleet at the Chile mine, the company was looking at engines to repower the trucks that would meet the emissions targets without compromising performance. Together with Detroit Chile S.A., the company found what it was looking for in the mtu Series 16V 4000 C05, which, in addition to significant emission savings, also offered other benefits for operations in the South American mine, Rolls-Royce says.

This project kicked off back in January 2018, with all 30 trucks in the fleet having now been equipped with mtu engines. An operating time of around 24,000 hours was calculated for each engine and, up to today, this fleet has surpassed 720,000 cumulative operating hours.

“Another and undoubtedly the biggest benefit of this repower project is the cleaner operation of these engines, or the tremendous reduction of emissions,” Rolls-Royce says. “To comply with local emissions regulations, the previous engines required to add a selective catalytic reduction (SCR) system to meet Tier 4 emissions. This includes additional maintenance and extra failure points that impact truck operation, the use of Diesel Exhaust Fluid and the potential for the catalyst to become contaminated at any time through regular operation of the truck, requiring replacement of the catalyst.

“Since the mtu engine meets Tier 4 emissions without the SCR system, this results in less downtime, less maintenance and lower operating costs.”

With the mtu Series 16V 4000 C05 engines, Anglo American is cutting CO2, particulate matter and nitrogen oxide emissions, according to Rolls-Royce. These engines comply with US EPA Tier 4 regulations, they consume less fuel than Tier 2 engines and still deliver the same power as previous engines.

Since the start of the repower project in January 2018, around 9,960 t of CO2, 91 t of particulate matter and over 3,000 t of nitrogen oxide have been eliminated, according to Rolls-Royce. As a result, the mining haul trucks meet local emission targets and bring Anglo Americans operations at the Los Bronces mine closer to the goal of net zero.

mtu Series 2000 and 4000 Tier 4 emission reduction technologies include a common rail injection platform, advanced electronics, two-stage turbocharging and exhaust gas recirculation

Rolls-Royce said: “An important factor in the decision for our solutions was the holistic approach: together with Detroit Chile S.A., we were able to provide engines, repower kits and ongoing comprehensive service that gets the most out of the mtu engine.

“The first of the trucks recently achieved over 24,000 hours of operating time, in mid-2023, and is still operating as expected. This proves the project is a strong, sustainable milestone not only for Anglo American, but also for other mining companies.

“The future has already begun and together, we are providing a cleaner future for the world.”

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

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.

DustGuard looks to clean up Australian mining market with WaterGasRenew distribution pact

DustGuard Corp, a provider of cloud-based protection and safety solutions for machinery and people operating in severe off-highway environments, has announced a strategic agreement with WaterGasRenew Pty Ltd as its exclusive distributor in Australia.

DustGuard’s namesake product, DustGuard™, continuously monitors the combustion air of high horsepower, off-highway engines for the presence of unsafe levels of dust particles that can reduce engine reliability and cause engine failure, the company says. DustGuard’s partnership with WaterGasRenew Pty Ltd will allow mining companies in Australia to benefit from reducing engine wear and damage related to dust intrusion, thereby improving fleet reliability and lowering engine repair or replacement costs, it says.

Jason Green, DustGuard Corp’s President, said: “We are very pleased to partner with WaterGasRenew in Australia. Their extensive experience in the mining industry combined with a proven track record of exceptional customer service will ensure that our technology delivers substantial improvements in fleet reliability for Australian mining companies operating in some of the most severe environments in the world.”

DustGuard was founded around the DustGuard engine protection solution. Other related technologies are being added to the company’s product lineup including CabGuard™, which monitors and alerts for dangerous particle, carbon monoxide, temperature and vibration levels inside operator cabs, and RoadGuard™, which monitors and alerts for haul truck vibration and g-load levels to protect tyres, suspension and frames while providing real time reporting of haul road conditions.

Bob Dixon, WaterGasRenew’s CEO, said: “We are privileged to be chosen to represent such an exceptional product and company. We have seen the DustGuard engineering team create unique solutions that satisfy both the technical and financial requirements of our customers. The DustGuard engine protection system is the first of a family of products that are designed to protect both current and future generations of mining equipment and operators. The Australian industry has always focused on the importance of safety, reliability and compliance and these principles are at the core of the DustGuard technology platform.”

Babylon Pump & Power to overhaul Premier Coal’s engines

Specialist resources services provider, Babylon Pump & Power Limited, says it has secured an agreement for supply of goods and services with Premier Coal Limited.

The agreement is for overhaul of Premier engines, supply of service exchange engines and labour support, as required. Based on quotations supplied and the anticipated schedule provided, Babylon estimates the total revenue over the three-year term, plus possible one-year extension, to be around A$16 million ($11.4 million).

The agreement comes with an initial three-year term, commencing from January 3, 2022, with the option for a one-year extension by written notice by Premier. The anticipated schedule included in the agreement specifies 44 engines over this three-year term.

Premier Coal claims to be Western Australia’s largest coal producer, mining about 4 Mt/y from its open-pit operation in the Collie Coal Basin. The company is managed by Yancoal Australia on behalf of its majority shareholder Yanzhou Coal Mining Company.

Premier’s mine has a 240 t truck and large shovel fleet along with state-of-the-art crushing, blending, and train and truck loading facilities, it says.

Cummins’ PrevenTech Mining keeps Komatsu trucks, wheel loaders going at Boliden mines

Cummins says its solutions are helping maximise machine uptime on trucks and wheel loaders running its engines at Boliden’s mines in Sweden and Finland.

In the vast open-pit copper mines here, the temperatures can drop as low as -40°C, testing the sturdiest of machinery working day and night extracting and hauling ore.

“It wouldn’t be so tough on the equipment if the thermometer stayed in roughly the same place for any decent length of time, but up there on the edge of the Arctic Circle it’s not unusual for a bitingly cold day to be followed by a more temperate one that feels positively tropical by comparison,” Cummins says.

The unpredictable swing in temperatures makes it difficult to keep equipment in full working order, with parts freezing and thawing, but it’s a challenge taken on by Cummins, which has signed service and maintenance agreements with the Swedish and Finnish distributors of Komatsu specialist mining equipment.

Cost-per-hour agreements – the first of their kind for Cummins in Europe – cover a total of 17 QSK60 Tier 4 Final engine-powered vehicles in Finland, while, in Sweden, a support contract covers a further nine examples of Komatsu’s 2,700 hp 930-E dump truck and a pair of the world’s largest wheel loaders, the L2350.

European DBU leader, Alok Joshi, and Sander Thorstensen, Cummins Leader for the Nordic region, arranged the contracts with the Komatsu distributors Hesselberg (Sweden) and SRO (Finland).

“We are relatively new to the mining sector in Europe,” Thorstensen says, “but all the feedback we have received so far has been incredibly positive, helped by our outstanding new PrevenTech® Mining telematics technology.”

PrevenTech Mining is a real-time digital monitoring and reporting system that provides an early warning of potential equipment operating issues. It helps plan maintenance and service, ensuring machinery is offline as little as possible, boosting productivity for, in this case, Boliden.

Janne Valmari is managing the Komatsu operations for Cummins Sweden. He has appointed two dedicated service technicians for Boliden’s Aitik copper mine just south of Gällivare in northern Sweden, and four technicians to cover Boliden’s Kevitsa mining operations across the border in Finland.

Valmari said the stream of data from PrevenTech allows the Cummins technicians to identify and diagnose performance issues faster and with greater accuracy, so they can see, for example, if an engine has been idling too long or revved too high, and can plan in the right fixes.

“It puts the mine owner in complete control, with no expensive surprises and benefitting from a higher return on their investment in product,” Valmari says.

Thorstensen added: “With their goal of keeping production running non-stop round-the-clock, I am certain Boliden sees the Komatsu-Cummins relationship as a core element of its strategy, and we will continue to strengthen our ties with Boliden and the Nordic mining industry in general.”

This is an edited version of an article that appeared in The Cummins Magazine

Rolls-Royce mtu Aiken facility to offer engine remanufacturing capabilities

Rolls-Royce has announced a $17.4 million investment at its mtu Aiken manufacturing facility in Graniteville, South Carolina, USA, for the addition of a new Remanufacturing and Overhaul Regional Center.

The planned 109,000-sq.ft (10,126 sq.m) expansion project will provide dedicated and streamlined remanufacturing and overhaul operations to support growth based on customer demand, it said. It will also result in the addition of about 20 new jobs.

To be built next to the mtu Aiken plant’s existing engine manufacturing operations, the new centre will bring currently outsourced workshop and warehouse operations in-house and expand them to provide remanufacturing of mtu Series 2000 and 4000 engines and components, the overhaul of mtu brand and customer-owned engines, plus internal and external rework services to help customers and distributors fine-tune maintenance and performance metrics, the company said.

Construction of the new centre is scheduled to begin later this year, with operations expected to begin in early 2023.

“Remanufacturing offers a wise lifecycle investment for customers, returning equipment to like-new condition and resulting in lower acquisition, maintenance and operation costs,” Rolls-Royce said. “Already performed at select global plant locations, the Rolls-Royce remanufacturing and overhaul process is designed to ensure optimal performance and durability, where used engines and assemblies are fully disassembled, cleaned and inspected, and then reworked and reassembled using all new parts to replace any outdated, worn, or damaged components.”

Dr Otto Preiss, Chief Operating Officer at Rolls-Royce Power Systems, said: “Investing in a remanufacturing and overhaul centre in the US is the next milestone in implementing our global strategy to optimise the value of our installed base, with regional centres and supporting workshops offering the best support for our customers.”

Marc Goldschmidt, Global Vice President Remanufacturing and Overhaul, added: “The new centre will fulfill regional and local customer needs using the global network and processes, following the remanufacturing and overhaul Lead Plant located in Magdeburg, Germany.”

The facility at Aiken will feature distinct work areas to carry out the remanufacturing and overhaul process: core management; cleaning and disassembly; measuring and inspection; rework; reassembly; test; and painting and packaging. Upon start-up, the centre will remanufacture all applications of mtu Series 2000, Series 4000, and Detroit Diesel 2-Cycle engines. The future aim is to add capabilities to support the company’s sustainable solutions such as battery containers, along with natural gas engines and systems.

Steve Blaszczak, Senior Manager, Remanufacturing and Overhaul – US, said: “Our investment in remanufacturing and overhaul solutions is also in line with our initiatives toward more environmentally-friendly solutions. By remanufacturing and overhauling engines, we are able to extend their useful life while also bringing them to the latest emissions standards. This benefits our customers as well as the environment.”

Since its opening in the fall of 2010, the mtu Aiken Plant has continued to innovate, invest and expand, the company said.

“What began with the production of Series 2000 and Series 4000 engines, has grown to include the assembly of military engines, the machining of parts and even the production of energy through its solar field and microgrid,” it said. “With an on-site research and development centre and now a new Remanufacturing and Overhaul Center, the mtu Aiken Plant covers the full circle of life for an mtu engine – from concept to second life (ie overhaul).”

Cummins launches QSK95 engine for ultra-class mining trucks

Cummins has launched the high horsepower QSK95 95 litre engine for mining, heralding it as the most powerful engine ever to be developed for ultra-class trucks.

Already in use in the marine and rail sectors, the mining engine comes with 2,837-3,281 kW of power (two versions – the higher rated QSK95 4400 and the QSK95 3800), 15,245-17,653 Nm of torque and is available in US EPA Tier 2 and Tier 4 Final configurations.

“The QSK95 offers class-leading cost of production and performance, with the availability that comes with legendary Cummins reliability,” the company said. Cummins has sold more than 1,200 of these engines across 36 different countries, it added.

IM understands the engine is being trialled in trucks like the 363 t Komatsu 980Es working at high altitudes in Latin America, with potential to be deployed in ultra-class trucks working in similar environments from other OEMs.

Cummins says the QSK95 delivers an “optimum power-to-weight ratio for 400 t (363 tonne) haul trucks”, a 3,800 hp rating for increased fuel efficiency and, on average, a 15% better life to overhaul, leading to longer engine lifespan with fewer overhauls.

“Specially designed single-stage turbocharging system means the QSK95 reliably maintains big power, even at high altitudes”, Cummins said. It also comes with lower vibration and less noise, thanks to the simple compact V16 design and stiff engine block.

Cummins power units set for take off

Cummins has launched new engine power take-off (PTO) capabilities for its B6.7 and L9 Performance Series Power Units that could help support underground mining equipment, as well as crushing and screening units.

Launched at Hillhead 2018, Cummins’ power units are available from 75-503 kW, and delivered as a complete and ready-made package. This comprises an engine, exhaust after-treatment system, radiator, and cooling system, plus auxiliaries such as mounting feet, hoses and an air cleaner.

More than 60% of the content is pre-approved, making the machine integration process simpler and quicker, according to the company.

Jeremy Harsin – Cummins Off-Highway Marketing Director – said: “Our Performance Series power units offer a flexible drop-in solution for manufacturers. The high-power density of our engines enables them to deliver high machine capability for hard-working applications such as crushing, screening and pumping.”

Examples of installations to date include the L9 Power Units powering Anaconda Equipment International’s new J12 and I12 mobile crushing machines.

“To increase the flexibility and capability of the power units, we are integrating new single and dual rear-engine power take-offs (REPTO),” Harsin said. “These complement their standard PTO capability used for items such as hydraulic pumps. We are also making these available on the base engines without the pack.”

As an example, fitted with the dual REPTO, the L9 will have a total drive capability of 560 Nm. This will make the engine capable of driving additional pumping capability through SAE B 2 and 4 bolt mounts, according to the company. Integrated into the flywheel housing, the dual REPTO is compact and has a minimal impact on engine packaging. Added weight is around 100 kg.

“For equipment manufacturers, they have the ability to efficiently drive more from the engine without the need for additional aftermarket systems,” Harsin explained. “This would support driving of hydraulic pumps for all sorts of machine functions from steering systems to fans, etc. It will reduce installation costs and complexity, for a more integrated solution.”

Babylon Pump’s business development efforts power up

Babylon Pump & Power Ltd has entered into a conditional agreement for the acquisition of diesel engine specialist Primepower Queensland for up to A$4.2 million ($2.9 million) in cash, shares, delayed performance payments and assumption of debt.

Mackay-based Primepower was founded in 2004 and is a specialist in Cummins engine repairs and rebuilds to the Queensland resources sector, Babylon said, with the acquisition complementing Babylon’s Western Australia-based diesel maintenance division and diesel generated power and pumping rental business.

The company has grown into a highly regarded specialist provider of diesel maintenance to the resources sector with a client base including Peabody, Fortescue Metals Group, BHP Mitsubishi Alliance, Anglo American, Wesfarmers and Minerva, Babylon said. Primepower generated unaudited annual revenue of around A$9.1 million for the year to June 30, 2019, and adjusted net profit of some A$600,000.

“The acquisition is Babylon’s first move into the eastern states and forms part of the company’s growth strategy, and provides an ideal platform to expand Babylon’s successful specialty equipment rental business into the East Coast,” Babylon said.

The acquisition provides Babylon’s Diesel Maintenance division with extra scale, in addition to technical expertise in Cummins engines to complement its expertise in Caterpillar engines, Babylon Executive Chairman, Michael Shelby, said. “[It] will be the perfect springboard to introduce our power and pumping rental offering to the East Coast market,” Shelby said. “The acquisition also provides commodity diversity, exposure to a larger client base, many with national operations, and will deliver a step-change in our operating scale and revenue.”

Shelby hinted that this may not prove to be the end of the company’s M&A efforts.

“The resource services and related sectors remain very fragmented, and it has become apparent that there are a number further potential complimentary acquisitions and new business development opportunities available,” he said. “While focusing on its core business, it is Babylon’s intention to explore thoroughly opportunities to expand in conjunction with its strong organic business growth.”

The consideration is comprised of cash on completion of A$1.7 million (adjusted pro-rata for net assets), A$600,000 in Babylon shares, assumption of a A$500,000 trade finance facility, deferred consideration of A$1 million over two years (adjusted for net asset value), additional deferred consideration of A$500,000 conditional on a revenue requirement of A$8.9 million being met in the 2020 financial year.

The Primepower purchase will see Babylon acquire net assets including stock and work in progress of A$3.1 million, and goodwill and plant and equipment valued at A$1.1 million. As part of the deal, Primepower founder and owner, Michael Donegan, will also remain a Primepower executive for a minimum 12 months.

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%.”