Transcript fuelcellventsavings.ppt

Ventilation Savings with Fuel
Cell Vehicles for Selected US
Metal/Non-Metal Mines
Gary Righettini
Pierre Mousset-Jones
Mackay School of Earth Sciences
and Engineering
University of Nevada-Reno
US Underground Metal/Non-Metal
Mines
• 173 metal/non-metal mines that use diesel
equipment; approximately 50% are stone
mines.
• 61% responded to survey in 2000
• 4,786 Diesel Units
• 641,000 Horsepower
• 68,000,000 liters of diesel fuel per year
The Case for Fuel Cell Powered Vehicles
• In most cases, surface and underground fans
are the largest consumers of electricity in
underground mines
• Fuel cells emit only water vapor.
• Emit less heat than diesel engines
• Require less ventilation than diesel engines
• Less ventilation means lower costs
Other Benefits of Fuel Cell Vehicles
• Fuel cell vehicles would make it unnecessary
to increase ventilation or use exhaust control
technology (DPM filters) to meet new DPM
regulations.
• If mines have to increase ventilation to meet
new DPM regulations, then the potential cost
savings with fuel cell vehicles would be even
greater than estimated in this study.
• Healthier work environment
• Fuel cell vehicles are quieter than diesel
vehicles
FUELCELL
LOADER
Phase 1: Cost/Benefit Analysis and Preliminary Powertrain Design
Complete: 31 January 2003
Cost: $891,669 (50% cost share)
Phase 2: Detailed Engineering Design
Start: 1 February 2003
End: 29 February 2004
Cost: $3,587,748 (50% cost share)
Phase 3: Fabrication, Vehicle Integration, and Vehicle Testing
Projected Start: 1 March 2004
Projected End: 30 September 2005
Projected Cost: $4.0 Million (50% cost share)
Copyright © 2003 Vehicle Projects LLC
PHASE 2 – DETAILED DESIGN
PARTNERS
• AeroVironment – Balance of Plant
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Caterpillar-Elphinstone – R1300 LHD
Caterpillar – Drive System, Hydraulics, System Integration
HERA – Metal-Hydride Storage
Nuvera – Fuelcell Stacks
CANMET – Technology Transfer, Fuelcell Stacks Life Data
Southwest Research Institute – Powerplant Software Modeling
Stuart Energy – Electrolysis Production Unit
Placer Dome – Stakeholder Input
Newmont – Stakeholder Input
Carleton University – LHD Software Modeling
Copyright © 2003 Vehicle Projects LLC
Design Criteria
200
6.0
150
5.0
Power - kW
100
4.0
50
3.0
0
2.0
-50
Tram
Level
Muck
-100
Tram up 15%
Tram
Level
Dump
Tram
Level
Tram
Dow n 15%
-150
0
50
Total Power
Copyright © 2003 Vehicle Projects LLC
100
150
200
250
Time - sec
Job Mean Power
300
Mean Kilowatts
350
Tram
Level
1.0
0.0
400
Energy
Energy - kW-hr
R1300 Duty Cycle
FUELCELL LOADER
PHASE 2 UPDATE
• Battery-hybrid design, 87 kW continuous fuelcell stacks, 70 kW
batteries
• Regenerative braking
• 20 kg usable hydrogen stored in metal hydride, saddlebag
configuration around powerplant
• Brushless Permanent Magnet (BPM) motor for traction drive
• Separate BPM motor for hydraulics
• Fuelcell stacks ordered 1 July 2003, delivered Dec 03
Copyright © 2003 Vehicle Projects LLC
Caterpillar Elphinstone R1300 LHD
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Detailed Engineering Design
Power Plant Fabrication and
Systems Integration
Safety and Productivity Evaluation
at a Mine in Nevada
March 2003 – February 2004
March 2004 – February 2005
March 2005 – August 2005
Powerplant Conceptual Layout
Fuelcell Power Module
Metal-Hydride Storage
Moisture Exchanger
Fuelcell Data Logger
Fuelcell Stacks
Power Conditioning
Electronics
Ni-MH Batteries
Copyright © 2003 Vehicle Projects LLC
Rear of Loader
Powerplant Conceptual Layout
Fuelcell Power Module
Fuelcell Stacks
Power Conditioning
Electronics
Metal-Hydride Storage
Ni-MH Batteries
System Controller
Copyright © 2003 Vehicle Projects LLC
DRS-EPT Traction Motor
Fuelcell Power Module Conceptual Layout
Fuelcell Data Logger
System Controller
Fuelcell Stacks
Structural Frame
Air Compressor
Air Compressor Motor
Moisture Exchanger
Power Conditioning
Electronics
Ni-MH Batteries
Copyright © 2003 Vehicle Projects LLC
Hydrogen Catalytic Converter
Layout – Side View
UQM SR286 100 kW
Peak (55 KW Cont)
Hydraulic Motor
Metal-Hydride
Storage
Axial Fan
Hydraulic Pump
DRS-EPT PA-44 Brushless Permanent Magnet
(BPM) 450 hp (335 kW) Traction Motor
Copyright © 2003 Vehicle Projects LLC
Criteria Used for Calculating Ventilation
Requirements with Fuel Cell Vehicles
• Minimum air velocity of 0.3 m/sec in drifts
where there is no blasting.
• Minimum air velocity of 0.5 m/sec in headings
where there is blasting.
• Limiting factors such as heat or gasses.
• VnetPC™ and CLIMSIM™ used for analysis of
ventilation changes.
VnetPC and CLIMSIM are trademarks of Mine Ventilation Services, Inc.
Mines in this Study
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Turquoise Ridge Mine, Nevada
Meikle-Rodeo Mines, Nevada
Deep Post Mine, Nevada
Henderson Mine, Colorado
Questa Mine, New Mexico
Galena Mine, Idaho
Lucky Friday Mine, Idaho
Avery Island Mine, Louisiana
Kerford Mine, Nebraska
The mines were visited prior to the MSHA
enforcement of the DPM regulation. Therefore,
the estimated ventilation savings could be
somewhat greater since some of the mines
might need to increase ventilation quantity to
assist in meeting the DPM 400 mg/m3 TC
regulation. Should the EC proposed interim
limit of 308 mg/m3 take effect, which could be
a lower value in the final rule, then it is likely
that increased ventilation will be needed by
many mines. This will result in even greater
benefits for using hydrogen fuel-cell powered
vehicles underground.
Turquoise Ridge Gold Mine,
Nevada
With Diesel Vehicles
• 3630 mtpd
• Longhole
stoping
• Intake 526.5
m³/sec.
• Parallel
intake airway
to reduce air
velocity
• 6.1 m dia.
exhaust
shaft, 671 m
deep, with 2
surface fans
• 9,304 diesel
horsepower
Turquoise Ridge Gold Mine,
Nevada
With Fuel Cell Vehicles
• Intake reduced
from 526.5
m³/sec to 230
m³/sec
• Exhaust Shaft
reduced from
6.1m to 4.27m
dia.
• One surface
exhaust fan
eliminated
• Parallel intake
airway
eliminated
Turquoise Ridge Gold Mine, Nevada
Savings with Fuel Cell Vehicles
• Annual ventilation power savings, $1.53
million @ $0.07/kwh.
• Capital cost savings of $3.445 million
(reduced diameter exhaust shaft, $1.32
million; eliminate parallel air intake drift, $1.9
million; eliminate one surface fan
installation, $0.225 million)
Meikle and Rodeo Mines, Nevada
With Diesel Vehicles
• 4080mtpd
• Bench stoping
and drift and fill
• Total intake
831m³/sec
• 18,748 diesel
horsepower
• Heat is a
concern, intake
air is cooled
Meikle Mine, 1750 Level
Branches used in CLIMSIM Model
1
6
Branches used in
Climsim Model
5
4
1
2
Production shaft station,
13.3Cº DB/10.6Cº WB
3
7
E. Footwall drift,
Q=23.6 m³/sec,
28.3CºDB/22.2CºWB
Calculating Heat and Water from a
Fuel Cell LHD Using CLIMSIM
* Fuel Cell LHD Heat = Diesel Power(kw) ÷ 2.8 x 1.2
** Water = (Diesel Water/Fuel) ratio x 1.9
* Diesel engine puts out 2.8 times as much total heat as an
equivalent electric motor in the Climsim model. Factor of 1.2
provided by CANMET.
** Factor of 1.9 provided by CANMET
Using CLIMSIM to Simulate Diesel and
Fuel Cell LHD’s
Diesel LHD
Fuel Cell LHD
28º C
Diesel LHD
Q = 23.6m³/sec
28º C
Fuel Cell LHD
Q = 20.06m³/sec
Meikle-Rodeo Mines, Ventilation Cost
Savings with Fuel Cell Vehicles
• Airflow reduction, 3.54m³/sec per heading x
25 headings = 88.5m³/sec.
• Total mine airflow reduced from 831m³/sec to
742.5m³/sec
• Annual ventilation power savings of $813,000
@ $0.07/kwh.
• Annual cooling plant savings of $225,800.
• Total annual savings of $1,038,800.
Deep Post Mine, Nevada
with Diesel Vehicles
• 1360 mtpd
• Drift and Fill
Stoping
areas
• 396.4 m³/sec
intake
through 5.5 m
dia. shaft and
decline
• 11,934 diesel
horsepower
• Heat is a
concern, but
intake air is
not cooled
Deep Post Mine, Nevada
with Fuel Cell Vehicles
•
CLIMSIM modeling
for stopes with
auxiliary ventilation
showed that air
quantity in each
heading could be
reduced from
11.8m³/sec to
8.45m³/sec and still
maintain design
26.7°C WBGT
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3.35m³/sec per
heading x 22
headings =
73.7m³/sec
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Total mine airflow
reduced from
396.4m³/sec to
322.7m³/sec
4150
level
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Annual ventilation power
cost savings of $627,600
@ $0.075/kwh
Henderson Mine, Colorado
With Diesel Vehicles
• 20,900 mtpd
• Panel Caving
• Total intake
991m³/sec
• Intake air
heated in the
Winter
• Radon gas in
cave area
• 21,217 diesel
horsepower
Henderson Mine, Colorado
8X C&D exhaust drifts
4-224 kW fans
4X A&B exhaust drifts
2-224 kW fans
Plan View
7755 Undercut Level
7700 Production Level
1
Long Section
1
7065 Haulage Level
Calculations for Ventilation Reduction on 7700 Production Level
All Quantities, Q, in m³/sec. Q at Exits based on V = 0.3 m/sec
Current Conditions
Production
Drift #
New Conditions
Q at
Entrance
Q at Exit
Q at
Entrance
Q at Exit
Ventilation
Reduction
at Entrance
1
11.8
11.8
4.76
4.76
7.04
2
9.06
9.06
4.76
4.76
4.3
3
15.43
15.43
4.76
4.76
10.67
4
11.7
9.3
5.99
4.76
5.71
5
17.42
14.87
5.57
4.76
11.85
6
19.4
10.01
9.22
4.76
10.18
7
21.29
16.61
6.1
4.76
15.19
8
20.88
10.34
9.61
4.76
11.27
9
15.57
12.2
6.08
4.76
9.49
10
21.14
5.76
17.47
4.76
3.67
11
16.28
9.25
8.37
4.76
7.91
179.97
124.63
82.69
52.36
97.28
Total
Ventilation Reduction at the Henderson
Mine
7700 Production Level
97.28 m³/sec
7755 Undercut Level
52.57 m³/sec *
7065 Haulage Level
38.32 m³/sec **
Total Reduction
188.17 m³/sec
* Based on a minimum V = 0.5m/sec
** Based on a minimum V = 0.38m/sec
(Lowest existing
velocity on this level)
Henderson Mine Ventilation Cost
Savings
• Total Mine airflow reduced from
991m³/sec to 803m³/sec
• Annual ventilation power cost
savings of $401,350 @ $0.04/kwh
• Annual intake air heating savings of
$25,500
• Total annual savings of $427,000
Questa Mine, New Mexico
With Diesel Vehicles
Future trackless
mining area
• Future
production
of 5445
mtpd
• Block
caving
• Total intake
141.6m³/sec
• 1,903 diesel
horsepower
Questa Mine
VnetPC plan view of future trackless
mining area
(airflows shown are for diesel equipment)
LHD drift 6
LHD drift 5
LHD drift 4
LHD drift 3
LHD drift 2
LHD drift 8
LHD drift 7
LHD drift 1
Questa Mine
Comparison of airflow quantities for diesel and
fuel cell LHD’s
Diesel Q,
m³/sec
Fuel Cell Q,
m³/sec
Reduction in Q,
m³/sec
LHD drift 1
7.4
3.1
4.3
LHD drift 2
7.3
3.1
4.2
LHD drift 3
7.3
3.1
4.2
LHD drift 4
7.2
3.1
4.1
LHD drift 5
7.2
3.1
4.1
LHD drift 6
7.3
3.1
4.2
LHD drift 7
7.1
3.4
3.7
LHD drift 8
7.0
3.3
3.7
Undercut level
13.6
10.8
2.8
71.4
36.1
35.3
Totals
Questa Mine Summary
• Total intake reduced from 141.6m³/sec to
106.3m³/sec with fuel cell LHD’s
• Annual ventilation power cost savings of
$65,000 @ $0.049/kWh
Galena Mine, Idaho
Coeur shaft
#3 shaft
Galena shaft
Callahan
shaft
Calladay
shaft
• 725 mtpd
• Conventional
and mechanized
cut and fill
• Total intake
82.45m³/sec
• Heat is a
concern; air
chillers on lower
levels
5500 Level
• 889 diesel
horsepower
Galena Mine
Mechanized cut and fill stopes, 5500 Level
•
CLIMSIM
modeling of up
ramp and
down ramp
stopes
accurately
predicted
actual air
temperature
measurements
Galena Mine
Comparison of ventilation quantities for diesel
and fuel cell LHD’s
Ventilation
quantity,
m³/sec, with
diesel LHD’s
Predicted dry
bulb
temperatures
with diesel
LHD’s
Ventilation quantity,
m³/sec, for fuel cell
LHD’s that will
maintain same air
temperatures as with
diesel LHD’s
5500 Level
up ramp
9.91
34.7°C
8.42
5500 level
down ramp
8.5
32.9°C
6.59
Total
18.41
15.01
Galena Mine Summary
• Ventilation can be reduced from 18.4m³/sec
to 15m³/sec in 5500 level stopes
• Total mine intake can be reduced from
82.45m³/sec to 79.05m³/sec
• Ventilation power cost savings of
$25,500/year at $0.04/kWh
Lucky Friday Mine, Idaho
Silver Shaft
#2 Shaft
4050 Level
•
476 mtpd
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Mechanized
cut and fill
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Total intake
107.6m³/sec
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Heat is a
concern; air
chillers are
used
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1264 diesel
horsepower
4900 Level
Lucky Friday Mine
Branches used in CLIMSIM model
Stope exhaust,
26.9°C/26.4°C
Fan
delivering
chilled air
to stope
Vent duct
discharge
temperatures,
26.7°C/23.6°C
Vent duct discharge
temperatures,
26.7°C/23.3°C
Lucky Friday Mine
Stope Modeling with CLIMSIM
Actual air
temperature
measurements
with diesel
LHD
CLIMSIM
prediction
for diesel
LHD
CLIMSIM
prediction
for fuel cell
LHD at
same
airflow as
diesel LHD
CLIMSIM
prediction
at 85% of
airflow as
diesel LHD*
Dry bulb
29.2°C
29.3°C
28.4°C
28.7°C
Wet bulb
28.3°C
28.2°C
27.5°C
28.1°C
* CLIMSIM predicted the possibility of condensation forming with fuel
cell LHD’s at airflows less than 85% of the airflow for diesel LHD’s
Lucky Friday Mine Summary
• CLIMSIM modeling showed that air flow in
stopes could be reduced by 15%
• Mechanized cut and fill stopes use about
50m³/sec of the total mine airflow of
107.6m³/sec
• Total intake reduced from 107.6m³/sec to
100.1m³/sec
• Ventilation power cost savings of
$63,000/year at $0.035/kWh
Avery Island Salt Mine, Louisiana
•
9000 mtpd
•
Room and Pillar
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Top heading
8.53m x 27.4m,
bench 16.76m
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Finished rooms
25.3m x 27.4m
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Total air intake
173.9m³/sec
•
Heat and
Pockets of CO2
and H2S
•
14,674 diesel
horsepower
Avery Island Salt Mine Summary
• No ventilation reduction possible because
of already low air velocities and possibility
of hitting pockets of CO2 and H2S.
• With Fuel Cell Vehicles there would be no
need to increase airflow to meet current
and new DPM regulations.
• Fuel Cell Vehicles would lower air
temperatures by 2º to 3ºC.
Kerford Limestone Mine, Nebraska
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7260 mtpd
Room and Pillar
6.7m x 10.67m rooms
Total intake 236m³/sec
11,589 diesel horsepower
Very low air velocities.
No ventilation reduction possible, but fuel
cell vehicles would make it unnecessary to
increase airflow to meet new DPM
regulations.
Summary of Economic Benefits
Mine
kWh of
Electricity
Saved Annually
Electric
Power Cost,
$/kWh
Annual Ventilation
Cost Savings
(electricity and
heating/cooling)
Capital Cost
Savings
Turquoise Ridge
21,900,000
0.07
$1,533,000
$3,445,000
Meikle-Rodeo
14,840,000
0.07
$1,038,800
Possible reduction in
airway sizes, main
exhaust fans, and
cooling plant
Deep Post
8,368,000
0.075
$627,600
$333,000 by
eliminating 2 main
exhaust fans, and
possible reduction in
airway sizes
Henderson
10,034,000
0.04
$427,000
$500,000 by
eliminating 3 main
exhaust fans, and
possible reduction in
airway sizes
Questa
1,327,000
0.049
$65,000
Possible reduction in
airway sizes
Galena
637,500
0.04
$25,500
Lucky Friday
1,800,000
0.035
$63,000