Tag Archives: R 9600

Liebherr advances Zero Emission Program with help of ABB, ENGIE

Liebherr, on the back of an increased industry focus on GHG emissions reduction, has announced at MINExpo 2021 that it is accelerating the implementation of its existing low carbon solutions and triggered future projects to offer completely fossil fuel free mining equipment options.

While much of this development will occur in house, the company has confirmed it is partnering with ABB on trolley assist infrastructure and ENGIE on integrating different renewable energy solutions into loading, hauling and dozing processes.

Liebherr Mining’s strategy to reduce GHG emissions will mainly focus on the operational phase of its machinery, as studies showed that more than 90% of GHG emissions over the complete lifecycle of the equipment occurred during this phase.

Liebherr Mining’s Zero Emission Program, which was established to develop these future solutions, is well aligned with the values of the Liebherr Group as an independent and responsible, family-owned company, it says.

The Liebherr Group has existing in-house core competencies, across all 13 product segments, in electrification, batteries, internal combustion engines, injection systems and alternative renewable fuels. Building from this experience, the Zero Emission Program has clear targets and a roadmap to achieve low carbon solutions for the full range of off-highway trucks and excavators in 2022, and fossil fuel free solutions for the majority of applications by 2030.

The Zero Emission Program strives to deliver long-term sustainable products and services, providing different options centred on environmental sustainability, safety, cost, flexibility and maintainability. Modularisation, along with an energy-type agnostic approach to drivetrains, are key elements in Liebherr Mining’s strategy, easing the transition for customers with the possibility to retrofit modules.

2022 target: Liebherr’s low carbon emission technology

Liebherr Mining has developed and offered electrification solutions for many years and is now about to finalise all initiatives to achieve its first 2022 target to offer low carbon emission solutions for its complete digging and hauling range.

The technologies, including the haul truck Trolley Assist System and electric excavator range, are consistently achieving proven results in the field to lower carbon emissions, according to the company. The newly introduced in-built Liebherr Power Efficiency control system has also shown excellent results since field operation began in 2019, the company says.

Trolley Assist System for Liebherr haul trucks

With the T 264 trolley components production-ready in 2022, all Liebherr trucks will be available with Trolley Assist System, providing a low emission solution for customers.

The Liebherr Trolley Assist System is, the company says, an effective first step on the road to zero emission mine sites of the future. Using an overhead pantograph or trolley bars to connect the electric-drive system to the electrical network, the Trolley Assist System offers increased truck fleet productivity, or reduction in fleet size, while maintaining yearly production when compared with standard trucks. A significant reduction of diesel fuel consumption is also made possible with the Trolley Assist System along with a reduction of the truck fleet CO2 emissions. However, this of course depends on the percentage of renewable energy content in the grid supplied power.

Oliver Weiss, Executive Vice President R&D, Engineering and Manufacturing, Liebherr-Mining Equipment SAS, outlined some of the company’s trolley assist operations at MINExpo 2021 today

Liebherr delivers proven field experience with 39 T 284 units fitted with the Trolley Assist System currently in operation on two different sites, with more to be commissioned in 2022. Liebherr is also the first company to run a 100 t truck under trolley, with a fleet of T 236 trucks running on a 5 km trolley line in Austria at the Erzberg mine – the longest trolley line in the world, according to Liebherr.

‘The largest range of electric excavators’

The Liebherr Group has over 30 years of experience in electric driven machines for earthmoving, material handling and mining applications. Today, Liebherr Mining says it is the OEM offering the largest range of electric driven excavators on the market. Ranging from 130 t to 800 t, the R 9150, R 9200, R 9250, R 9350, R 9400, and R 9800 are all available as electric drive versions. The electric drive R 9600 will soon be available.

Liebherr electric excavators are existing and already proven solutions helping customers to build future sustainable mine sites, it says. Focusing on reliability, maintainability and maximum safety, Liebherr’s engineering teams strive for solutions requiring minimum change to existing energy infrastructure and operational behaviour on customer sites. Thanks to 70% of parts commonality with diesel versions, Liebherr also offers complete retrofit options for existing machines.

To offer better machine mobility and safety for the workforce on site, Liebherr has developed a cable reel option for all electric drive excavators either in backhoe or face shovel. The cable reel is completely autonomous and has a capacity of up to 300 m depending on the excavator type. Furthermore, Liebherr proposes an operational concept for excavators with cable reel in backhoe application, particularly in double benching operations.

Liebherr Power Efficiency

Liebherr says it is continuously improving and upgrading its standard machines to enable the transition to emission reductions. Liebherr Power Efficiency (LPE) is the most recent built-in technology upgrade making this productivity and sustainability contribution.

Starting with Generation 7, all Liebherr mining excavators will be equipped with LPE as standard. This specific engine and hydraulic management system drastically reduces fuel consumption by up to 20%.

The system:

  • Adapts piloting processes according to operator requirements;
  • Electronically controls pressure and oil flow;
  • Has increased efficiency of the control valves and the new Liebherr pumps;
  • Has a fully integrated engine control system;
  • Reduces hydraulic losses and load profile of the engine for increased component lifetime; and
  • Reduces energy consumption without impact on the machine performance.

Based on research and development, Liebherr is able to provide size-equivalent machinery with higher production rates and less fuel consumption.

“In fact, the combination of LPE together with the improved productivity of the R 9600, has shown 29% less fuel consumption per tonne of produced material over a one-year production study, compared to its predecessor, the R 996B,” Liebherr says. “Expressed in fuel efficiency, tonnes per litre, this corresponds to a 40% better utilisation of the fuel.”

These efficiencies allow Liebherr excavators to set new benchmarks in its respective classes and are a very important enablers for any kind of future drive train, as they significantly reduce the effort for cable handling or refuelling and storage of alternative fuels, the company says.

Pathway to zero emission solutions

As second step, Liebherr is now targeting to offer completely fossil fuel free mining equipment for hauling, digging and dozing by 2030. This development will take into consideration the GHG emissions over equipment’s full lifecycle, as well as the overall well-to-wheel energy ecosystem. The company is also taking into account the operational mining process conditions that influence the right energy type choice.

Liebherr will develop three drivetrain options to achieve near zero emissions for its off-highway trucks: battery power module, internal combustion engines powered by renewable fuels, and H2 fuel cell-battery power module.

Drivetrain electrification through battery combined with trolley assist is already underway, according to the company.

Despite some challenges, Liebherr sees also an opportunity that the propulsion energy can be provided by using hydrogen fuel cell-battery hybrids.

Research and development for internal combustion engines operating with renewable-based alternative fuels is progressing very well within the Liebherr Group, with Hydrogenated Vegetable Oil (HVO) as an approved fuel for machines powered by Liebherr engines as a first step.

Hydrogen combustion engines are also currently being tested in Liebherr’s factory in Switzerland. The methanol combustion process has been developed for large displacement engines and is ready to move towards serial engine industrialisation based on market demand, according to the company. Additionally, the ammonia combustion process is under investigation, with Liebherr seeing high potential in the usage of ammonia for heavy mobile, high energy demanding machines and gensets.

Liebherr mining excavators and dozers will also both have the option to be powered by internal combustion engines running on alternative fuels, along with the already existing electric drive version for excavators.

To achieve near zero emissions for the mining dozer and excavator, it is also crucial to use the most efficient drive system to reduce fuel consumption. The Liebherr hydrostatic drive system already achieves up to 20% improved fuel efficiency compared with mechanical competitor products, it says.

Despite this, Liebherr is currently in the process of comparing efficiency of an electric drive on a dozer prototype with hydrostatic drive efficiency. Given Liebherr’s expertise in both hydrostatic and electric AC drive systems, the company says it is in the best position to choose the most appropriate option for the best drive system for the near zero emission solution.

To accelerate the process and ensure the best solutions will be offered, Liebherr is partnering with industry experts for its Zero Emission Program.

ABB, a leader in power and automation technologies, develops state-of-the-art technology and equipment for overall electrification of mine sites and supports Liebherr’s customers and the company with a particular focus on trolley assist infrastructure deployment.

ENGIE, a renewable hydrogen, low-carbon energy and services company, will jointly with Liebherr evaluate the different renewable energy solutions, in particular renewable hydrogen and hydrogen-derived fuels, for loading, hauling and dozing processes. This cooperation ensures that an integrated well-to-wheel approach is basis to define the best solutions for the mining industry, Liebherr says.

With concept studies nearly finalised for trolley-battery hybrid, and ammonia and methanol for internal combustion engines, Liebherr expects to undertake field validation from 2024-2026, followed by the integration of proven fossil fuel free solutions from 2026-2030 into the entire range of mining machines.

Liebherr launches its R 9600 hydraulic mining excavator, part of a new generation

After years of development, the Mining Division of the Liebherr Group has launched today the new R 9600 hydraulic excavator. This 600 t excavator, it says, sets new standards in the open-pit mining market. The successor of the popular Liebherr R 996B has entered the market after gaining a year of field experience in Australia, the largest market for 600 t class excavators. This new development builds on years of customer-centric research and is based upon the successful R 9800 800 t excavator. A total of eight units will be operating in Australia by the end if 2021. The R 9600 will enter serial production at the end of this year.

Customer input has played an important and pivotal role in the development of this new machine. Engineering, sales and marketing teams have collected feedback and insights from mine site equipment operators, maintenance personnel and procurement groups as well as executive management to have a clear understanding of the challenges they meet every day.

The new R 9600 aims to reach the highest standard in terms of safety, sustainability, performance, lifetime, total cost of ownership (TCO), ease of maintenance and more. After testing the first prototypes at the factory proving grounds in Colmar, France, in early 2020, the first R 9600 pre-series excavators started operating in iron ore and coal applications in Australia. Liebherr, together with its two very important customers, BHP and Thiess, started the partnered validation of the first two units in the field. Backed by this succesful validation phase, the R 9600 is ready to enter the global market.

Diverse offering of powertrains including electric drive

The R 9600 is equipped with two QSK50 Cummins engines with advanced combustion technologies. Understanding that fuel costs form the major portion of the TCO for mining machines, Liebherr has developed and implemented LPE  (Liebherr Power Efficiency) solutions. These proprietary management systems for the engine and hydraulic system controls substantially reduce fuel consumption without compromising the overall productivity of the machine. These new features grant also an additional step toward the Liebherr emission reduction solutions. For emission-regulated regions, a US EPA Tier 4 Final/EU Stage V compliant version is available with the latest SCR after-treatment technology. Complying with stringent emission regulations, the SCR system reduces nitrogen oxides by injecting a liquid reductant into the exhaust stream. An electric drive version will be available soon, a productive choice for mine sites having the required electrical infrastructure.

Weight-optimised attachment

The R 9600 attachment makes use of smart component design such as the patented “EVO” backhoe bucket, hydraulic cylinders, shift levers, bucket links and attachment pins. The result is an increased overall production rate without compromising component lifetime. In standard backhoe configuration with a Heavy Duty wear package, the R 9600 comes with a 37.5 m³/49.1 yd³ bucket to deliver an ideal truck/shovel match with Liebherr mining trucks. It loads 190 t trucks in three passes, T 264 240 t trucks in four passes, T 274 300 t trucks in five passes and T 284 375 t trucks in six passes. The excavator is also available in face shovel configuration equipped with a 37 m³/48.4 yd³ shovel, as standard with a Heavy Duty wear package.

Long-lasting performance

Designed to be used in all applications globally, the R 9600 is built to last over 80,000 machine operational hours. Further improving machine reliability, the uppercarriage structure is a completely new development. The robust undercarriage, with a fatigue resistant steel structure, is enhanced with a new hydraulic track tensioning system. The standard sealed for life heavy-duty carrier and track rollers incorporate the patented roller path design and registered track pad design. As an Original Equipment Manufacturer (OEM), Liebherr has built a solid reputation in the development and production of high quality components for mining applications. The R 9600 benefits from this reputation through reliable components that are developed and manufactured by Liebherr. The R 9600 utilises the latest quality control systems to ensure the best reliability and highest performance.

The latest cabin generation

The R 9600 has a brand-new cabin designed by operators for operators – it is a first-class, state of the art 14 m³/150 ft³ working space. The cab design reduces vibrations and limits noise to 69 dB, providing a comfortable working environment for the operator. To allow for the best possible working conditions, Liebherr engineers have placed the cab of the R 996 successor back on the left side, standardising with other excavators in the range. The operator’s seat has been positioned as far left as possible in order to provide the best operator visibility of the attachment and working area. Ambient and low-level LED lights make working at night easier and safer. The operator station is user-friendly and equipped with modern touch screen displays. The air conditioning system for the cabin is a modular design concept which is easily exchanged as a rotable component, as single or dual air conditioning systems are available. To further enhance the operator comfort, vacuum cleaner, premium cooled seats, HEPA filtration system and many more features are available. The R 9600 offers a superior machine perimeter visibility system comprising of four cameras at strategic locations on the rotating uppercarriage. The dedicated monitor inside the cabin provides continuous 270° vision around the machine.

Assistance Systems and on-board controls

Setting new standards in the mining industry, the R 9600 is equipped with the Liebherr Assistance Systems. These advanced on-board applications are designed to support the operators in becoming more efficient through analytics and actionable insights from live data. The Truck Loading Assistant helps the operator attain optimal productivity and efficiency. With 99% measurement accuracy, the system measures the instantaneous bucket payload and provides real-time information to the operator. The Truck Loading Assistant strategises the number of passes required to achieve the target payload of the truck, and also provides a progressive update in achieving the strategy.

In addition, to provide operators and customers with productivity KPIs of the machine performance, the severity of the application and the operational conformance of the machine is realised in real-time on the machine. The first Liebherr hydraulic excavator (HEX) Automation Product introduced to the mining industry is the Bucket Filling Assistant, an adaptive or semi-autonomous digging product available as an option for the backhoe version of machines. It allows for easier and faster bucket filling with a consistent bucket fill factor, load after load, even in the toughest digging conditions. As a result, the overall productivity improves while the operator’s fatigue level is reduced.

Designed for safe 24/7 operation and maintenance

Liebherr product development is centred around protecting the customer’s most important assets. The R 9600 was designed with respect to global safety standards for operators and maintenance personnel, ensuring that safety remains a top priority at all times. The upper carriage of the R 9600 has been designed to allow for quick and easy maintenance activities, and is accessible via a hydraulically controlled ergonomic 45° stairway. Enlarged walkways with handrails and non-slip perforated steps allow for safe and convenient inspections and maintenance at all levels of the machine, including engine and powertrain components. All major parts have been designed and positioned to allow easy access and quicker maintenance. The central service flap provides fluid and lubricant access to all components and systems, which reduces potential downtimes. Component and system refill and drain points of the R 9600 are accessible from ground level with quick couplings and depressurising valves.

R 9600 continues to write the success story

The R 9600 builds on two strong models of the Liebherr mining excavator portfolio: the R 996B and the R 9800. The first R 996 was introduced in 1995, followed by the R 996B in 2000.

“This very popular machine has been the benchmark in the mining market for the past 25 years, especially in Australia, where over 70% of these excavators have or are operating today accumulating 5.5 million machine hours,” the company said. “The R 9600 is not only further building on the success of its predecessor but is also inspired by its big brother, the popular 800 t R 9800, sharing a long list of components that have been proven on the R 9800 over the past 10 years. As with all Liebherr mining equipment, the predecessor models R 996 and R 996B will continue to be supported with remanufacturing, repair and customer support services for the duration of the machine’s lifetime.”