Tag Archives: MTU

Zest WEG helps South Africa platinum miner power up

Zest WEG, looking to accommodate the space constraints of a South African platinum mining customer, is constructing a large diesel powered generator set to be delivered later this year.

The capacity of the 2,500 kVA genset will make it the largest unit yet to be fully load-tested at the company’s genset manufacturing facility in Cape Town, South Africa, according to Craig Bouwer, Projects and Product Manager at Zest WEG.

“In addition to functional testing, we will be equipping ourselves to conduct load testing to 11 kV on this unit,” Bouwer says. “With load-banks in-house, we will be stepping the voltage down to 400 V during the testing, and drawing on MV specialists to ensure a safe and reliable process.”

The genset is a highly technical solution to match the customer’s specific needs, he says. Based on the available space, it is housed within a 12 m ISO shipping container with the electrically-driven radiator mounted on the roof.

Prime-rated at 11 kV and powered by an MTU diesel engine, the genset has been designed in close consultation with the customer over a number of months. Having concluded the engineering design, construction is currently underway in Cape Town.

Bouwer highlighted the detailed and time consuming nature of engineering design for a project of this magnitude and complexity: “Stringent technical requirements demanded lengthy and ongoing collaboration not only with the customer, but between our engineering team and production operations,” he said. “The customer was particularly pleased with our flexibility and the extra effort we applied to ensure the optimal technical returnables for the project.”

As one of the few South Africa-based original equipment manufacturers capable of undertaking a customised genset of this capacity in-house, Zest WEG will also be supplying the control and protection panel from its range of electrical equipment and products.

“To enhance safety and ergonomics, the control panel is in its own compartment within the ISO container,” Bouwer says. “A 1,000 litre bunded day tank has also been installed inside a separate compartment within the container, including a fuel cooler and filtration system.”

The COVID-19 lockdown has had minimal impact on the work schedule, he noted, as planning and communication with the customer could continue regardless, dealing with various technical clarifications. To facilitate the transportation of this large unit to site, it will be shipped as three separate components: the genset, radiator and exhaust system. Once installation is complete – a process that Zest WEG specialists will supervise – its experts will conduct the cold and hot commissioning, and hand over to the customer.

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.

Rolls-Royce Power Systems brand restructuring sees MTU name focused on product lines

The Rolls-Royce Power Systems business unit, with its core brand MTU, will present itself more clearly in the future as an integral part of the British Rolls-Royce engineering group. A new brand architecture is currently evolving, which will be visibly implemented as of autumn with the launch of the new MTU website. The company is one of the leading global suppliers of mining engines.

“The new, clear brand structure will support the PS 2030 strategy of the Power Systems business unit and the global growth path. Rolls-Royce will be the corporate brand and the employer brand,” the company said. “Consequently, the companies within the business unit that include MTU in their names will be given a new designation. MTU, as the brand name customers are familiar with, will continue to be used to identify the company’s products and solutions. The current MTU Onsite Energy brand for decentralised power supply systems will be integrated into MTU.”

One of the first visible steps to be taken will be the renaming of four operating companies, which manufacture products and solutions: MTU Friedrichshafen GmbH will thus become Rolls-Royce Solutions GmbH in autumn 2019. This will be followed by MTU America Inc, which in future will operate as Rolls-Royce Solutions America Inc. Today’s MTU Onsite Energy GmbH in Augsburg will become Rolls-Royce Solutions Augsburg GmbH and MTU Onsite Energy Systems GmbH in Ruhstorf will be renamed Rolls-Royce Solutions Ruhstorf GmbH. The remaining subsidiaries will successively be given new designations based on the above examples. The products of Bergen Engines will also be part of the new brand architecture.

“The new brand architecture will provide clarity and improve the recognition of our company and its products,” said Andreas Schell, CEO Rolls-Royce Power Systems. “Our new profile is a clear commitment to Rolls-Royce, as its second largest business unit. By the same token, Rolls-Royce is committed to our MTU brand, which is something we are proud of,” Schell added.

“The new brand profile will be visible with the launch of the MTU brand’s new website in autumn of this year. Additionally, company employees will be given e-mail addresses with the domain [email protected], plus new working clothes that will emphasise the affiliation of the MTU brand with Rolls-Royce.”

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.”