Preliminary Design for a Mobile Ammonia Genset for Use with Electric Mining Excavators

Abstract

Given global temperatures are expected to rise past the Paris Agreement’s 2°C limit, Liebherr Mining aims to develop products that progress their Zero Emission Mining strategy. This project therefore selected the major components required by a mobile ammonia-fuelled genset under certain operating conditions and assessed the proposed design against existing solutions.

The project was built on findings from a business pre-study and the Liebherr Mining Zero Emission Mining Concept Definition. A further literature review covered excavator operation, genset design, ammonia combustion, and existing solutions.
A use case defined the operating conditions, and the resulting requirements were validated with industry through a Voice of the Customer survey. Key genset components were then selected to meet the design requirements. It was proposed that a partner company should manufacture the final product. Several potential partners were short-listed, ranked, and met with, and a final recommendation was made. To validate the design, it was compared to market competition using the design requirements as comparison metrics.

The proposed design included a Liebherr A9912 ammonia engine, a Stamford S7L1D alternator, and a Deep Sea controller mounted on a wheeled trailer, with an expected output of 1163 kW to 1932 kW. Fuel would be supplied by a 20 m3 on-board NH3 fuel tank and cracker. BGG was recommended to manufacture the product. The market comparison ranked the design higher than all other examined solutions.

Given the successful project completion and approval by stakeholders, the design is planned to be further developed and commercialised.

Popular Abstract

Ammonia-Powered Gensets: A Green Mobility Solution for Electric Mining Excavators

Can you picture a world where mining machines have no emissions? This study aims to make this possible by proposing a mobile ammonia-fuelled generator set for powering electric mining excavators, promising zero emissions and increased mobility.

Everybody knows about the devastating implications of rising global temperatures, and the mining sector is facing growing pressure to adopt greener technologies. This master's thesis therefore introduces an innovative green power solution in-line with Liebherr Mining's ambitious Zero Emission Mining strategy.

The thesis focuses on designing a mobile ammonia-fuelled generator capable of powering Liebherr's electric mining excavators. Typical electric excavators rely on cables connected to the power grid, limiting their mobility. The proposed genset would eliminate this dependency, letting excavators move freely and reducing downtime caused by cable adjustments.

Key components identified include the Liebherr A9912 ammonia engine, a Stamford S7L1D alternator, and a Deep Sea controller, all mounted on a wheeled trailer for manoeuvrability. Designed to meet demanding mining operations, the genset has a maximum power output of around 1900 kW. It features a dual fuel system combining ammonia and hydrogen, supplied by an onboard 20 m3 ammonia tank with a cracker to convert some ammonia to hydrogen, enabling 12 hours of continuous operation.

Mining operations require robust, reliable power solutions which is challenging for current green technology options. By shifting to an ammonia-based system, the study therefore addresses several critical needs including flexible, efficient, and carbon-free mine operation. The relevance of this work also lies in its tangible progress toward sustainable mining practices, contributing to broader environmental goals and aligning with international regulations. Beyond mining, the technology can be adapted by other industries, paving the way to further applications of ammonia-fuelled engines.

The choice of ammonia as a fuel is particularly intriguing. While ammonia is often associated with fertilizers, its potential as a green fuel is gaining attention. Ammonia combustion in engines, combined with small-scale cracking technology, allows for efficient energy conversion with minimal emissions. This dual use of ammonia—both as a fuel and a hydrogen carrier—highlights its versatility and potential to drive sustainable energy solutions.

The study began with a comprehensive literature review. A use case defined the operating conditions, and industry validation was conducted through a Voice of Customer survey. Key components were then selected based on the requirements, and potential manufacturing partners were evaluated. Finally, the proposed design was compared against market alternatives.

This thesis provides a compelling blueprint for integrating mobile ammonia gensets into electric mining excavator operations. The successful implementation of such technology offers a pathway to more sustainable mining practices and could set a precedent for green innovations across various sectors. As industries worldwide seek to reduce their carbon footprints, the insights from this study could be a game-changer in sustainable energy development.

• author: Petty, Leanne Helen
• supervisor: Martin Tunér
• organization: Department of Energy Sciences
• alternative title: Ammonia-Powered Gensets: A Green Solution for Electric Mining Excavators
• course: MVKM01 20241
• year: 2024
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Ammonia internal combustion engine, Alternative fuel generator set, Electric hydraulic excavators, Zero emission mining solutions
• report number: ISRN LUTMDN/TMHP-24/5594-SE
• ISSN: 0282-1990
• language: English
• id: 9165463
• date added to LUP: 2024-06-24 14:23:49
• date last changed: 2024-06-24 14:23:49