First Mode has completed a large 8 t mega battery module at its Perth, Western Australia battery R&D operation for its next generation fuel cell demonstration mining truck. The truck is based on a Komatsu 930E which is already at its Centralia, Washington test site in the US. The battery will be integrated into the truck along with Ballard hydrogen fuel cell modules. Next year will see First Mode also convert a Komatsu 830E to zero emissions operation.
This is another major step in First Mode’s path to decarbonising heavy equipment – and will be the second retrofitted mining truck after the initial nuGen™ Haulage Solution truck, converted 930E truck DT74, which is still running at Anglo American’s Mogalakwena platinum mine in South Africa 18 months after introduction and is now part of the commercial fleet. During its first year, operating under typical mining conditions, the truck demonstrated full payload capacity of 300 tons during pit runs, achieving performance parity with its diesel counterparts, while its increased efficiency allowed for high operational speeds with the same power. Pit runs included loading under a 100 ton capacity shovel, climbing a 10% grade fully loaded, and traveling a typical haul route distance of 11 km before successfully dumping loads into the crusher.
The latest First Mode battery packs are being designed to be able operate in all of the harsh conditions faced in mining, from +50°C in the Pilbara to -50°C in northern Canada. They are equipped with tailored battery and thermal management systems with energy delivery controlled using dedicated software. Earlier this year, First Mode and ABB announced that ABB’s BORDLINE® ESS batteries are being assembled into the larger battery packs used in the construction of hybrid hydrogen and battery powerplants to power First Mode’s new ultra-class haulage trucks.
The FCEV option is just one of three retrofits First Mode offers. It is also offering a Hybrid Electric Vehicle (HEV) option with regenerative battery pack. When the truck is descending a hill, it uses its wheel motors as brakes. The energy generated is captured by the batteries and later used to help power the truck. This regenerative braking and power reuse cuts down on fuel usage and carbon dioxide emissions by up to 30%, depending on conditions. The HEV diesel engine, radiator, and fuel tank are untouched by the HEV retrofit. No new support infrastructure is needed, so the HEV is aimed at being a first step in the miners’ decarbonisation journey.
Then it is offering a full Battery Electric Vehicle or BEV retrofit. The BEV main batteries are charged through regenerative braking and through a static multi-megawatt fast charging system. The radiator is used to maintain acceptable operating temperatures for the batteries and their associated power electronics.
