Investigation of decarbonization options for load and haul equipment in quarry mining with case study Ipoh quarry, Malaysia

Abstract

The importance of decarbonization in various industries is growing significantly, especially when it comes to LHD equipment in the minerals and metals industry. Conventional diesel load and haul (LHD) equipment used in quarrying and mining operations have drawbacks that result in the emissions of hydrocarbon and greenhouse gases that need to be reduced to reach the Net Zero Emissions scenario. Decarbonization options that could replace diesel equipment include battery electric vehicles, green hydrogen, and alternative fuels. This project aims to give an overview of current and near future available decarbonization methods and to analyse the environmental benefit, cost effectiveness and technological feasibility of these alternatives to diesel fuel. The case study used to simulate and compare the three different decarbonization options is a mountaintop marble quarry based in Ipoh, Malaysia. A comparison has been made with Ipoh located in Malaysia and a hypothetical situation of Ipoh located in France to show the true potential of decarbonization as Malaysia does not incentivize businesses to reduce emissions due to their subsidies on the use of fossil fuel. Malaysia’s energy mix consist of primarily unabated fossil fuels.
The proposed workflow involves an extensive literature review of current and near-future decarbonisation technologies to replace diesel equipment and to create a haulage network based on block model data using the software Xpac Quarry solutions and its Haulnet package. Diesel equipment is imported from the Quarry solutions database and used as a base case to compare BEV and trolley assist simulations. Hydrogen and HVO fuel consumption have been calculated manually to obtain NPVs and associated emissions. An investigation into required infrastructure and energy requirements has been done to accurately define costs and resulting total CO2eq emissions.
The results indicate that replacing diesel at Ipoh with any of the decarbonization methods will result in a negative NPV as the infrastructure requirements need extensive capital investment of which the payback period often exceeds the life of mine. The least expensive method to implement HVO fuels, followed by BEVs and green hydrogen. Furthermore, it has been found that using BEVs instead of diesel at Ipoh is more environmentally polluting because producing 1 kWh of electricity is more polluting than producing the same energy worth of diesel. Green hydrogen is the least polluting method with no greenhouse gas emissions associated with it, followed by alternative fuels. When investigating the technological feasibility of the three main decarbonization options, hydrogen is the furthest away of being technologically feasible as from now. No green hydrogen using water electrolysers has been produced at an industrial scale, and a lack of technical expertise and infrastructure is present regarding distribution, transportation, and storage. Currently, no hydrogen LHD equipment is commercially available currently, and the same applies to BEVs that could replace the current equipment used at Ipoh. To bridge this gap, alternative fuels are the best option, but the market is competitive, and supply is limited. This project has given a good overview of current possibilities and clearly shows today’s options for decarbonisation and where industries stand with respect to infrastructure and equipment.