Theodore Levitt once said: ‘Creativity is thinking up new things, innovation is doing new things.’ As it relates to the electrification process of industrial vehicles, it’s a bit of both. The task is the same whether the vehicle uses a conventional diesel engine or an electric one, so you need creativity to discover the technological breakthroughs that will ensure it works just as well in application and an innovative approach to organizing its workflow to ensure its success.
This article takes stock of why 2023 seems to be the right time for an aluminium producer, Rio Tinto, to undertake an ambitious project like the electrification of an Anode Hauler fleet and the motivation behind embracing this change and the challenges of switching from diesel to electric engines from theory to reality. The enthusiasm that comes with the industrial drive towards net-zero emissions goes to show Quebec’s aluminium and equipment manufacturers have a pivotal role to play.
Challenges in Anode Hauling
Hauling anodes may seem simple. However, when we take a closer look at the operating environment of aluminium producers, we quickly come to understand the complex challenges that come with operating electrified hauliers in this environment.
A host of factors need to be considered. For example, the weight of the payload, the impact of charging on continuous operations, the effect of a magnetic field on the hauler, coactivity, the payload’s specific handling requirements, associated risks of hauling materials in confined spaces, etc. As such, it’s essential to have a fleet of sturdy, reliable and safe haulers.
The task haulers perform can be rather repetitive. However, they are essential to the operation of the smelter and require extreme vigilance. Equipment manufacturer EPIQ MECFOR’s haulers are more than just tractors and trailers, they’re a key piece of the puzzle that links different parts of the aluminium smelter to make it function efficiently.
Rio Tinto is working with EPIQ MECFOR to test its Electric Anode Hauler, the model MTE, in one of its smelters, to test recharges, maintenance, and autonomy of the vehicle in an industrial environment with magnetic fields. This is one example of how Rio Tinto supports business partners in their technological developments through financing, networking, and technological expertise.
Genesis of an industry trend and how it translates in the North American aluminium industry
Since 2016, discussions have been taking place, leading the industry to start restructuring and establishing standards to mobilize towards the decarbonization of aluminium production. Consumers want more responsible products and are asking for more traceability. Aluminium is turning green and big players are leading the way.
For example, in 2021, Rio Tinto launched its START Responsible Aluminium initiative, the first sustainability label for aluminium using blockchain technology. Now, many initiatives are converging to reduce energy consumption and new technologies are emerging with a focus on reducing carbon footprint. Put simply, the greenhouse gas reduction race is underway.
Important initiatives to reduce the overall environmental footprint of the aluminium industry are taking place across the value chain and emerge from close collaboration between smelters, customers, suppliers, equipment manufacturers, employees, and the community.
With this in mind, EPIQ MECFOR set out to understand the readiness of the industry to shift to electric engines, conducting a small-scale market study in 2019. At that time, it turned out that vehicle electrification wasn’t the main priority for the industry; other major projects were on the agenda.
So too, factors such as the installation of charging stations in often crowded environments, availability of battery technology that would allow sufficient autonomy to carry heavy loads, and the requirement to recertify maintenance crews to be able to work on electrified equipment all posed barriers to adoption.
Based on discussions with industry players, EPIQ MECFOR knew it was only a matter of time before the request for electrical engine industrial vehicles would re-emerge.
The right time to live the green dream
The decarbonization of its operations is at the heart of Rio Tinto’s business strategy, with clear and ambitious objectives: achieve a 50% reduction of emissions by 2030 and transition to net zero by 2050. The scale-up of the joint venture ELYSIS, a carbon-free smelting technology, will play a critical role in that strategy, as does their commitment to invest in technology and innovation across the entire aluminium production supply chain. The decarbonization of transportation is one of them.
There are multifaceted challenges to this decarbonization process across all levels. The transition to ‘green’ energy Anode Haulers requires facility modifications (e.g.: charging station) along with new skills for maintenance teams. The involvement and cooperation of the end-users, aka the aluminium producers, is necessary.
EPIQ Machinery followed suit by appointing a team mandated to convert its diesel engine-powered anode haulers to battery-powered. To better address the above concerns, EPIQ MECFOR partnered with Rio Tinto for the electrification project of its anode haulers, allowing testing of the EPIQ MECFOR Electric Anode Hauler, the model MTE, in a real operating environment and to develop a sensible strategy for a transitioning plan. By working together, we know that we can accelerate progress and continue to play an important role in the fight against climate change.
The leap towards electrification centres on two key aspects:
Type of driving, accelerations/decelerations, speed management, energy recovery to optimize the active load of the equipment, etc.
Defining a transition strategy (e.g. choice of charging strategy, charging station location, the possibility of a switch to a fleet of 100% electric haulers or necessity of a gradual transition, vehicle maintenance plan, limitations linked to space constraints, etc.).
EPIQ aims to develop equipment that will deliver the same product performance with a similar experience for the operator. Also, it is possible to consider an electric EPIQ MECFOR MTA/MTC tractor and trailer design or to think of a non-articulated single-hulled model that would resemble the auto-guided hauler (AGV) model which could be more easily converted later. In fact, once the transition to electric equipment is well underway, some producers will be ready to step up with auto-guided haulers.
In short, there are multiple roads to net-zero emissions; converting heavy-duty mobile equipment is one of them. EPIQ Machinery is equipped to offer innovative hauling solutions. The team has the capacity and the knowledge to develop electric haulers. We appreciate the ‘close to customer’ approach with a cooperative mind-set.
EPIQ Machinery strives to be a strong link in this constantly evolving aluminium production ecosystem. We understand that saving energy is saving money and preserving our planet’s resources. In the end, efficient equipment pays off.
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