Tag Archives: Rolls-Royce

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

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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.”

Rolls-Royce and Sustainable Development Capital to offer ‘Energy-as-a-Service’

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Rolls-Royce has agreed to a cooperation with the global investment firm Sustainable Development Capital LLP (SDCL) to jointly offer ‘Energy-as-a-Service’ solutions that can help accelerate the take-up of more sustainable power in applications such as mines.

The agreement, signed at the World Climate Conference (COP26) in Glasgow on November 11, allows Rolls-Royce to provide customers with electricity and/or heat, generated by a sustainable and efficient energy system, as a subscription service, removing the need for customers to secure up-front infrastructure finance or operate the system themselves.

“The provision of ‘Energy-as-a-Service’ where a customer pays for heat and power through a subscription model, represents a very attractive way to improve access to sustainable power,” Rolls-Royce said. “Rolls-Royce will work with SDCL and other partners to design, finance, build, commission and operate new projects.”

SDCL has more than a decade of experience of developing and financing clean and decentralised energy infrastructure projects in the UK, continental Europe, North America and Asia. Rolls-Royce, through its Power Systems business unit, has a portfolio of microgrid systems that bring together renewable energy sources such as solar and wind power with mtu-branded battery storage and gensets to ensure reliable power generation. It is currently developing fuel cell systems and making its existing mtu engines compatible with sustainable fuels, paving the way for net zero microgrid solutions within the next two years.

Examples of ‘Energy-as-a-Service’ projects can range from providing sustainable and reliable power for communities in remote areas that are not connected to a public power grid; to industrial parks that want to be supplied with green power as well as emergency back-up and mines that want to replace old, inefficient, equipment to meet new regulatory requirements and make use of as much renewable energy as possible.

Andreas Görtz, Vice President Power Generation at Rolls-Royce Power Systems, said: “Energy-as-a-Service is particularly interesting for companies that need to adapt their energy supply to new circumstances – be it an expansion for which more power is needed or an adaptation to new regulatory requirements, such as emissions guidelines. Because this often involves investing in equipment, such as a microgrid, that requires expertise to operate, it’s a challenge for customers to do this on their own. By offering Energy-as-a-Service, we can help them overcome that challenge.”

The portfolio of energy systems that can be made available through ‘Energy-as-a-Service’ to provide electricity and/or heat, ranges from smaller plants using combined heat and power units to battery containers and complex microgrid solutions, Rolls-Royce said. The existing mtu product range will be expanded in the coming years to include new technologies such as hydrogen-powered engines, fuel cell systems and combustion engines that can be operated with sustainable fuels such as e-diesel and hydrotreated vegetable oils.

Perry Kuiper, President Sustainable Power Solutions at Rolls-Royce Power Systems, explained: “Industrial companies and other businesses that rely on environmentally and climate-friendly energy can avoid ever-increasing energy and grid connection costs as a benefit from our new Energy-as-a-Service offering. We use our own new mtu technologies, our system expertise and our global network of partners and service locations to offer our customers an efficient and reliable energy supply on their way to climate neutrality. With SDCL, we have a strong financial partner on board that has successfully developed and financed clean energy, energy efficiency and decentralised energy infrastructure projects since 2007.”

Rolls-Royce to step up hydrogen content in mtu power generators

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Rolls-Royce says it is further developing its mtu gas engine portfolio for power generation and cogeneration to run on hydrogen as a fuel and, thus, enable a climate-neutral energy supply.

Generation sets powered by mtu Series 500 and Series 4000 gas engines can, today, be operated with a gas blending of 10% hydrogen, but, beginning in 2022, operation with a hydrogen content of 25% will be possible, the company said.

Perry Kuiper, President Sustainable Power Solutions at Rolls-Royce Power Systems, said intensive tests on test benches and pilot installations at customer sites in 2022 will lead to Rolls-Royce continuously marketing new mtu Series 500 and Series 4000 gas engines beginning in 2023 for use with up to 100% hydrogen, and, on a design to order basis, conversion kits to allow already installed gas engines in the field to run on 100% hydrogen.

Last month, Rolls-Royce and FLANDERS signed an MoU to develop hybrid mining truck retrofit kits for hybridising mining trucks with mtu engines, batteries and hybrid control systems.

Andreas Görtz, Vice President Power Generation at Rolls-Royce Power Systems, said: “The decarbonisation of power generation requires reliable, flexible, but also climate-neutral, power plants to supplement the fluctuating generation from wind and sun. We assume that natural gas will initially be the primary fuel in the development of the hydrogen ecosystem, but we see hydrogen as technically and economically possible. That is why we continue to develop our gas engines for use with green hydrogen – whether as a 10 or 25% admixture or for 100%.”

Rolls-Royce says fuel cells powered by 100% green hydrogen can also play an important role in future energy supply in combination with renewable energies.

At its Friedrichshafen headquarters, Rolls-Royce’s Power Systems division has installed a 250 kW fuel cell demonstrator, which will be used to test and present future CO2-free energy systems to customers. The entire hydrogen ecosystem, including the infrastructure for supply, conversion, test benches and future production, is also being mapped in the company’s own plants, thus building up expertise, it said.

Rolls-Royce’s Power Systems division, through its climate protection program, “Net Zero at Power Systems”, has set itself the target of saving 35% of greenhouse gas emissions by 2030 compared with a 2019 baseline using new technologies.

This near-term target plays an important role in the Rolls-Royce Group’s ambition to achieve carbon neutrality by 2050 at the latest, it said.

In addition to new technologies, a key element in achieving these targets is the certification of key mtu engine products to run on sustainable EN 15940 fuels such as e-diesel and second-generation biofuels as early as 2023, the company added.

Rolls-Royce and FLANDERS sign MoU to develop hybrid mining truck retrofit kits

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More details have emerged on Rolls-Royce and FLANDERS Electric’s plan to develop a retrofit solution for hybridising mining trucks with mtu engines, batteries and hybrid control systems, and FLANDERS drive train solutions at MINExpo 2021 this week.

As IM revealed last month, Rolls-Royce has been working on concept of a hybrid drive system for mining trucks, with  FLANDERS Inc power electronics and controls to be used for retrofits.

The two companies have now signed a Memorandum of Understanding enabling them to offer a scalable retrofit kit for hybridising mining trucks in a wide range of mining applications.

With its brand mtu, Rolls-Royce says its business unit Power Systems is a leading provider of advanced integrated and sustainable power solutions for a wide variety of applications, including mining equipment. FLANDERS, meanwhile, develops and sells electric motors and generator systems, as well as automation and control systems for heavy industrial applications.

The companies plan to leverage their extensive experience to offer customers hybrid solutions that aim to save fuel and reduce the CO2 footprint of mining trucks as well as optimising vehicle power performance and efficiency, enabling more climate-friendly and safer mining operations, they say.

John Oliver, CEO and Chairman of the Board of Flanders, said: “Improving our customers’ operations, lowering their costs while enhancing their energy footprint, is a win for the mining industry and for the environment as a whole. We are excited to partner with Rolls-Royce Power Systems to deliver an industry leading hybrid power solution that will help our customers achieve their energy or carbon reduction goals.”

Scott Woodruff, Vice President for Mining and Oil & Gas at Rolls-Royce Power Systems, said: “We are excited to shape the mining industry’s sustainable future together with Flanders and further leverage our advanced hybrid technologies, which are already proven in the rail industry. Together we will offer our customers integrated, future-oriented, hybrid solutions.”

The mining truck hybrid concept recovers braking energy, using the mtu EnergyPack battery system. This energy is then fed back to power the wheel motors, allowing the diesel engine to be downsized. The smaller engine reduces fuel consumption and CO2 emissions by up to 30%, helping mining customers to achieve their emissions reduction targets, while optimising their operations, it says. The hybrid concept also includes the DC/DC converters which interface the battery system with the DC link of the truck. The system is highly modular and scalable for trucks of any size, working anywhere in the world, according to Rolls-Royce.

Rolls-Royce mtu Aiken facility to offer engine remanufacturing capabilities

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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).”

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

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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

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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.”

Rolls-Royce makes microgrid investment as energy storage takes off

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Rolls-Royce has made an investment in Berlin-based start-up company Qinous GmbH as it looks to increase its exposure to the rapidly developing energy storage sector and bolster its microgrid offering.

Marcus Wassenberg, CFO and Labour Director at Rolls-Royce Power Systems, said: “As a strategic investor, the aim is to set up a partnership with Qinous for the development of innovative energy storage solutions and together offer cleaner solutions designed to meet tomorrow’s needs.”

The increased use of renewable energies has exacerbated the challenge of how to maintain a reliable energy supply, when weather conditions are unfavourable, to meet demand, according to Rolls-Royce.

Autonomous electricity networks, or microgrids, combine cogeneration plants, diesel- and gas-powered gensets and renewable sources with batteries and a control system that links up all the elements in an energy management system to optimise the energy usage technically and economically.

Qinous has gained considerable experience in the integration of battery storage and energy systems in microgrids in more than 30 projects worldwide and has already integrated MTU Onsite Energy systems from Rolls-Royce in such projects, Rolls-Royce said.

The investment made by Rolls-Royce is to expand the existing product portfolio and strengthen global sales and marketing activities, the company said.

Andreas Schell, CEO of Rolls-Royce Power Systems, said: “We have identified our customers’ needs in terms of autonomous energy supply systems that are efficient, reliable and environmentally friendly. For this reason, we are now adding turnkey microgrids to our current portfolio.

“In addition to the diesel and gas gensets supplied by MTU Onsite Energy, together with our partners like Qinous we will now offer battery containers, include renewable power generation plants, and combine that with intelligent control. This strengthens our position as a provider of innovative power solutions able to supply our customers with microgrid systems tailored to their specific requirements.”

Microgrids can supply energy autonomously to remote locations, such as mining operations or islands that have no grid access.

When operated in parallel with existing infrastructure, they can provide an environmentally friendly supply of electric power to industrial companies or local communities while simultaneously providing support for the public grid.

“The most crucial component of a microgrid is an intelligent control system, which determines what power sources are to be used at what time in order to supply energy to the end user or top-up the battery system. This is done in accordance with the customer’s preference; for instance, whether they prefer low-cost electricity generation, the supply of renewable energy, or high rates of power availability,” Rolls-Royce said.

Rolls-Royce Power Systems is now setting up a microgrid demonstrator in Friedrichshafen, Germany, that will assist in the design of microgrids that meet customer specific requirements.