Shell builds a winning consortium to accelerate the electrification of off-road mining vehicles
Oct 12, 2022
Shell’s new end-to-end mining electrification pilot offering aims to help the mining industry decarbonise, by reducing emissions without compromising on operational efficiency or safety.
London: Today, Shell announced the establishment of its nine-member consortium to create a new pilot offering of electrification solutions for mining sites. Skeleton, Microvast, Stäubli, Carnegie Robotics, Heliox, Spirae, Alliance Automation, Worley and Shell have come together to introduce Shell’s Mining Electrification Solutions for Off-Road Vehicles – an end-to-end and interoperable electrification system that reduces emissions without compromising on efficiency or safety, while aiming to be cost competitive versus diesel-powered operations. The pilot offer combines an innovative, high-powered battery solution with ultrafast charging and a standardised micro-grid energy system where the required solution can be complemented with renewable electricity generation on-site or through the grid.
As an alternative energy source, electrification offers off-road industries the immediate potential to shift away from a long-standing reliance on diesel. For hard-to-abate sectors like mining, this is critical, since mobile equipment comprises between 40 and 50 per cent of mining’s CO2 emissions.1 By 2030, it is estimated that a battery-electric haulage truck will: lower total cost of ownership (TCO); involve 20 per cent lower maintenance costs; and incur 40 per cent lower fuel costs than existing diesel trucks.1
“It is increasingly clear that no one, single organisation can solve decarbonisation alone,” said Grischa Sauerberg, Vice President, Sectoral Decarbonisation & Innovation at Shell. “The need for a collaborative effort is particularly evident within carbon-intensive industries like mining, where the challenges are great but the opportunities are even greater. To overcome these challenges and unlock these opportunities, Shell is helping to bring together some of the sector’s most innovative companies – with electrification proving an important first step towards the shaping of a clear decarbonisation pathway.”
Shell’s Mining Electrification Solutions for Off-Road Vehicles consists of:
- Power provisioning and microgrids: aim to provide a consistent and reliable supply of renewable power in a safe and stable manner
- Ultra-fast charging: taking approximately 90 seconds via flexible, hardwearing and resilient, on-site, ultrafast charge-points, which provide assets with continuous operations in the most challenging of environments
- In-vehicle energy storage: through a combination of advanced battery and capacitor technologies that aim to deliver long lifetimes, ultra-fast charging and high performance
As a result, mining operators are set to benefit from an integrated electrification solution that:
- Is end-to-end, covering the full journey of the electron from generation to delivery in the drive train
- Is interoperable between different Original Equipment Manufacturer (OEM) make and models, giving mining operators greater flexibility
- Is modular in design to allow mining customers the opportunity to tailor solutions to their specific needs
- Reduces emissions without compromising on operational efficiency or safety
“The challenge of decarbonisation is immense, but not impossible – providing collaboration and innovation go hand in hand at all times,” said Sauerberg. “Both of which were on show during the recent Charge On Innovation Challenge, which saw the Shell-led consortium of equipment manufacturers, technology partners, industry experts and Shell Energy – our in-house supplier of renewable power - push the boundaries of what is possible for hard-to-abate sectors like mining. Our winning solutions are proof of how, together, the industry can help power progress by realising the full potential of the technologies available to us – whether that is through electrification, digital tools or low-carbon fuels.”
As Shell works together with customers and partners towards a new, cleaner era for mining, it is important to attract leading companies from other sectors of the economy who also want to make a positive contribution to reducing emissions.
Contact email@example.com to learn more about Shell’s Mining Electrification Solutions for Off-Road Vehicles and the pilot offer.
Notes to Editors
About Shell Mining
With 80,000+ employees across 70+ countries, Shell works with global industries to accelerate the transition to net-zero emissions by providing more and cleaner energy solutions. Shell’s target is to become a net-zero business by 2050, which supports the ambitious goal to tackle climate change laid out in the UN Paris Agreement: to limit the rise in average global temperature to 1.5° Celsius.
To help transform industries, Shell has created the Shell Sectors & Decarbonisation (S&D) business. This is comprised of teams with specific sectoral experience who support companies that operate in hard-to-abate sectors to avoid, reduce and mitigate their emissions. Shell S&D provides these customers with the products and solutions required today, while working together to meet their fast-evolving needs.
Shell Mining works across the entire mining value chain – from hauling to processing and beyond – to identify and develop decarbonisation strategies, pathways and solutions that help unlock efficient operations and sustainable practices. Shell’s sectoral approach allows the mining team to apply its deep industry knowledge and expertise, while working closely with customers to develop highly tailored solutions. In doing so, Shell Mining sees collaboration as a critical part of innovation and a crucial lever for emissions reduction across the sector.
About Charge On Innovation Challenge
BHP, Rio Tinto and Vale, are the founding patrons of an exciting collaboration, the Charge On Innovation Challenge. Facilitated by Austmine, this was a global initiative for technology innovators to develop concepts for large-scale, haul truck electrification systems to help the mining sector reduce its consumption of diesel fuel and significantly cut emissions from open-pit mines. The challenge was born out of the industry requiring a safe solution that could be applied across the many and varied mines, mine infrastructure and truck manufacturers.
Skeleton is a Global Cleantech 100 company and a global technology leader in fast energy storage for automotive, transportation, grid, and industrial applications.
For us, developing and producing the best energy storage solutions is a means to an end: helping companies to reduce CO2 emissions and save energy.
We work with some of the largest companies in the world - from European automotive companies, industrial equipment OEMs to truck fleet operators and aerospace prime contractors. Our products decrease CO2 emissions and fuel consumption, improve power quality, and empower wider electrification of the biggest industries globally to fight climate change.
Our supercapacitor and SuperBattery energy storage technologies, based on patented curved graphene, represent the biggest technological advancement in the industry in the last 20 years and the use of this innovative material provides our products with an unparalleled advantage in power and energy density.
Skeleton Technologies Group has four main locations: its manufacturing in Großröhrsdorf, Saxony, sales in Berlin, materials development in Bitterfeld-Wolfen, Saxony-Anhalt, Germany, and electrical engineering in Tallinn, Estonia. In 2024, we will open the largest supercapacitor factory in the world in Markranstädt, Germany.
Skeleton is the global technology leader in fast energy storage for automotive, transportation, grid, and industrial applications. Skeleton has also developed “SuperBattery technology”: the highest power-to-energy ratio technology available on the market, with 65 Wh/kg and up to 12 kW/kg.
Founded in 2006 as a research and technology driven company, Microvast (NASDAQ:MVST), has evolved into a global leader in the design, development and manufacture of battery solutions for mobile and stationary applications. Microvast provides a broad portfolio of fast-charging lithium-ion battery solutions, with different chemistries, performance characteristics and price points to meet the diverse requirements of its customer base. Microvast is renowned for its cutting-edge cell technology and its vertical integration capabilities which extend from core battery chemistry (cathode, anode, electrolyte, and separator) to modules and packs.
Since placing its first battery systems into operation in electric buses more than a decade ago, Microvast has expanded its business to serve a broad range of commercial, passenger and specialty vehicles, including mining processes and power equipment as well as grid-scale energy storage applications. Microvast’s batteries have been operating in more than 28,000+ all-electric and hybrid-electric vehicles in more than 220 cities among 28 countries around the world.
Stäubli is a global industrial and mechatronic solution provider with four dedicated Divisions: Electrical Connectors, Fluid Connectors, Robotics and Textile, serving customers who want to increase their productivity in many industrial sectors. Currently operating in 29 countries, Stäubli is an international Group with representatives in 50 countries on four continents. Their global workforce of 5,500 shares a commitment to partnering with customers in nearly every industry to provide comprehensive solutions with long-term support. Originally founded in 1892 as a small workshop in Horgen/Zurich, today Stäubli is an international Group headquartered in Pfäffikon, Switzerland.
About Carnegie Robotics
Carnegie Robotics (CRL) is a leading provider of rugged sensors, autonomy software and platforms for defense, agriculture, mining, marine, warehouse & energy applications. CRL is situated on the 5-acre campus of a former steel mill in the heart of Pittsburgh PA (USA) where all engineering, product design, full-scale testing, and robust in-house production occur.
Heliox provides world class smart energy management solutions that are tailored and scalable within a fast changing e-mobility landscape. We are working towards a sustainable world where a seamless charging experience is the standard for every electric vehicle, and this transforms the way we power our everyday.
Founded in 2009, Heliox is the market leader in fast charging systems within public transport, e-trucks, marine, mining and port equipment. In 2017, the company installed one of Europe’s first and largest rapid charging networks for the e-bus fleet in Eindhoven, The Netherlands; and over the past two years, has created ‘model city’ energy ecosystems around the world in Den Bosch, Netherlands, Glasgow, Scotland and Montgomery County, Maryland (USA).
Operating globally, the company is headquartered in the Netherlands with local presence in Germany, Sweden, United Kingdom, Italy, Spain and the United States.
Spirae is an innovative technology company that develops solutions for integrating renewable and distributed energy resources within microgrids and power systems for economic optimisation, resiliency enhancement, and decarbonization. Headquartered in Fort Collins, Colorado, Spirae has developed, refined and validated its control platform and menu of customer-driven applications through numerous full scale and pilot projects in the Americas, the Caribbean, Europe, Africa, and S.E. Asia.
About Alliance Automation
Alliance Automation is a multi-disciplined industrial automation and electrical engineering company. Alliance Automation specialises in delivering value added solutions, consultancy and support to customers and partners in Mining, Oil and Gas, Water and Waste Water, Industry and Infrastructure market sectors both in Australia and overseas.
Alliance Automation provides concept to completion turn-key project delivery with system lifecycle support resulting in the development of long term trusted partnership with clients. Alliance Automation marries their extensive industry knowledge with available technologies, resulting in robust and value based solutions for clients.
Worley delivers more than consulting, engineering, procurement and construction services: we are delivering a more sustainable world. Every day, our global team helps our mining customers get one step closer to solving our planet’s complex challenges. We navigate the journey together to net-zero greenhouse gas emissions. And we keep pace with digital transformation. Our work today ensures we have a tomorrow. One in which we can all thrive.
OREN is a digital services and solutions provider, collating data and using advanced analysis that helps identify and remove operational inefficiencies to streamline costs, cut emissions and accelerate decarbonisation progress for the customer.
About Shell Energy
Shell Energy provides innovative, reliable and cleaner energy solutions through a portfolio of gas, power, environmental products and energy efficiency offers to businesses and residential customers.
The energy market is changing across the globe, driven by growing energy demand and an urgent need to curb emissions. Attitudes are changing, and the demands placed by businesses and households in relation to energy supply are evolving. From energy producers, asset owners, traders and wholesalers, commercial and industrial customers to individual households, Shell Energy customers are seeking increasingly efficient, innovative and cleaner energy solutions. Shell Energy offers customers the reliability, simplicity, scale and innovation to help them find and navigate the energy solutions that best suit their needs.
End to End solution: Shell supplies the electricity to the OEM vehicle as well as facilitating the implementation and operations of an electrified haul-truck fleet. Solutions include: next generation in-vehicle energy storage, high-capacity fast charging systems, automated charging connectors, microgrid site energy management, mine-site integration specialist and renewable power provisioning.
Reduce emissions: Electrified mobile equipment does not emit any CO₂ emissions whilst operational and therefore offers a reduction vs. diesel operated machinery.
Without compromise in operational efficiency: Shell's electrification solution can have multiple charge points available to charge a haul-truck within a typical haul-truck cycle whilst a vehicle is typically stationary, such as whilst being loaded, meaning a haul-truck may run continuously.
Without compromise on safety: For Shell, HSSE is a key priority when designing individual components of the solution and integrating them in a system. For example, HSSE safeguards such as on-board & Remote Emergency Stop, Object Detection and Avoidance, Charge Connector Status, Temperature & Coolant Flow Monitoring aim to be implemented. Ultracapacitors that we intend to use for energy storage have better fire safety characteristics than Lithium-ion batteries.
Ultra-fast charging: Ultra-fast means Energy Transfer of 400 kWh in ~< 90 sec and assumes peak power delivery of 24MW.
Charge-points are resilient: Charge points adhere to IP55/IP2X industry standards, charge point standards are specifically designed to work in the most challenging environments.
Electrification has lower TCO (vs. diesel): TCO is calculated using a variety of factors including cost of maintenance and the cost of energy (electricity). This is dependent on the cost of electricity, availability of electricity supply to a mine site and the cost of implementing an electric fleet.
Interoperability: Shell is working with Original Equipment Manufacturers (OEM) and solution provider partners to standardise our solution specifications across multiple OEMs and solution providers to ensure a broad as possible compatibility.
Renewable Power: Renewable power refers to electricity generated from renewable sources like wind or solar. Renewable power generation is not possible in all situations.
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