Energy efficiency and CO2 emission comparison of alternative powertrain solutions for mining haul truck using integrated design and control optimization

Abstract

The heavy-duty mining haul truck (MHT) with hundreds tonnage could emit hundreds of times emissions over a passenger vehicle. The heavy burden of emissions and continuous global warming force the mining industry seeking clean powertrain solutions for MHT. This research optimizes several emerging clean powertrain solutions for a typical 240 tonnage MHT using integrated design and control optimization method, and compares the energy efficiency and carbon dioxide (CO2) emission to the benchmark MHT with a diesel engine and diesel-electric drive. The well-established components model and optimal control theory support the integrated optimization under given operation profile. Currently, the battery electric solution could cut 63 percent usage cost incorporated with the lithium-ion battery degradation cost and reduce 21 percent well-to-wheel CO2 emission, making the battery electric solution a competitive candidate. Though the hydrogen fuel cell emits 26 percent less CO2 emission than the diesel counterpart, the high investment cost and degradation cost hinder its wide application. Further improvement of hydrogen production, capital cost and durability of fuel cell, and fast-charging of lithium-ion battery could release huge potential in cleaner MHT. The study provides an approach to quantitatively compare clean powertrain solutions and identify the optimal powertrain parameters for cleaner MHT.