The Elements of Innovation Discovered
The Elements of Innovation Discovered
Metal Tech News - March 11, 2024
Hitachi Energy and BluVein are collaborating to accelerate the development of reliable e-rail charging for up to 400-metric-ton electric mining trucks.
The quest for net-zero carbon emissions has mining companies and heavy equipment manufacturers brainstorming on innovative ways to electrify mining trucks often designed to haul hundreds of tons of rock per load. A dynamic charging system developed by Australia-based BluVein offers a solution that can be retrofitted to all brands of electric trucks hauling material at both surface and underground mines.
Building a 400-metric-ton electric mining truck is fairly straightforward, and every major heavy equipment manufacturer on earth has developed electrified versions of its haulers. The challenge comes with ensuring these trucks have enough juice to haul their heavy loads without the costly downtime associated with charging or battery swapping.
BluVein's solution is to charge mining trucks on the fly. More specifically, to deliver electricity to the motors and batteries when needed most – while fully loaded and making the slow and arduous climb from the depths of the mine.
"We help mine sites shift to electric truck fleets by providing a cost-effective, easy-to-install, on-the-go charging technology for battery-powered heavy mine vehicles," said BluVein Managing Director James Oliver.
The BluVein solution, engineered with flexibility in mind, has captured the interest of both mining companies and heavy equipment manufacturers alike. This includes Hitachi Energy, which has recently entered into an agreement to help accelerate the commercialization of this cutting-edge e-rail charging system.
"This strategic collaboration with BluVein will enable our mining customers to trial next-generation dynamic charging solutions vital for achieving net-zero emission targets without compromising on operating practices or productivity," said Marco Berardi, head of grid and power quality solutions and service business at Hitachi Energy.
Leveraging 12 years of research and development of electrified highways by the Swedish tech company Evias and 25 years developing mining machinery, robotics and power systems by Australian engineering firm Olitek, BluVein has developed a slotted rail charger that can be used at open-pit and underground mining operations.
BluVein's dynamic charging system includes an e-rail designed to be installed overhead in underground mines or alongside the roads leading out of open pits, and a charging arm called the BluVein Hammer that automatically connects and disconnects equipment to the rail.
BluVein Rail is designed for easy installation and reconfiguration to meet the evolving charging needs at a mine and has been engineered to keep the equipment connected to the rail even on rough roads.
When installed in areas where trucks need energy the most – fully loaded and climbing out of a pit or underground mine – the BluVein system charges the battery and powers the drive motors during the slowest and most energy-intensive section of the circuit. On downhill sections, electric truck batteries can gain even more charge with regenerative braking systems that are being installed on most models.
"This results in smaller, lighter batteries, the elimination of battery swapping, and better management of battery life through proper charging," said BluVein Chief Technology Officer Richard Bach.
The BluVein charging system has piqued the interest of mining companies looking for viable solutions to transform their mining fleets to electric.
Agnico Eagle, BHP, South32, Northern Star Resources, and Vale are among the large mining companies that have partnered with BluVein.
The technology has also attracted the attention of heavy original equipment manufacturers (OEMs), who see the advantages of this system, which is compatible with all types of battery-electric mining equipment.
"A critical element of BluVein is the understanding that mine sites operate a range of different vehicles," said Bach. "The project team successfully joined with a number of OEMs to ensure that BluVein is able to integrate across mixed mining fleet."
Hitachi, a major mining equipment manufacturer based in Japan, is the latest OEM to join BluVein's quest to commercialize its innovative charging system.
On March 5, Hitachi Energy signed a memorandum of understanding to accelerate the electrification of heavy haul mining fleets.
"We believe this new collaborative approach will deliver on our common goal to accelerate the transition to all-electric mining and a carbon-neutral future," said Berardi.
In addition to its interest in integrating BluVein with battery-electric Hitachi mining equipment, Hitachi Energy is collaborating with its development by complementing BluVein's leading-edge e-rail and automated connection system with its own advanced power electronics and digital solutions to power and monitor the whole system.
BluVeinXL, the company's largest system, is designed for up to 250-metric-ton trucks. The Hitachi Energy enhanced system is expected to have the capacity to safely deliver electricity to 400-metric-ton trucks, which rank among the largest of the mining haul trucks in use today.
"This MoU supports BluVein's mission of partnering with a technology leader to deliver a universal dynamic connector that facilitates the removal of fossil fuel from mines and helps propel the industry globally to meet its decarbonization goals," said Oliver. "Together, we are helping the industry move to a more sustainable and responsible future."
BluVein and Hitachi Energy's integrated technology is expected to soon be on display at the BluVein Proving Grounds currently under construction in Queensland, Australia.
With more than 16 years of covering mining, Shane is renowned for his insights and and in-depth analysis of mining, mineral exploration and technology metals.
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