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Gladstone Ports Corporation Limited – Hybrid Initiatives For Heavy Equipment

Gladstone Ports Corporation Limited – Hybrid Initiatives For Heavy Equipment. Malcolm Pollock. 2006 Federal Government – Energy Efficiency Opportunities Programme Legislation. Compulsory participant if using greater than 0.5 Petajoules energy per annum

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Gladstone Ports Corporation Limited – Hybrid Initiatives For Heavy Equipment

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  1. Gladstone Ports Corporation Limited – Hybrid Initiatives For Heavy Equipment Malcolm Pollock

  2. 2006 Federal Government – Energy Efficiency Opportunities Programme Legislation • Compulsory participant if using greater than 0.5 Petajoules energy per annum • Approximately 200 companies in Australia in this category • Gladstone Ports Corporation energy usage – 60% diesel, 38% electricity, 2% other fuels • 23 D11 dozers at R G Tanna coal terminal used 90% of diesel consumed

  3. Caterpillar D11T Dozer Pushing Coal For Ship Loading

  4. Energy Reduction Initiatives • Update the fleet of dozers – 7% reduction in fuel consumption for latest model • Reduction in idle time from 30% to 15% by reducing need to run 850 HP engine for cabin cooling • Potential savings - $55,000/machine/year giving total of $1.265 million per year (Fuel and servicing costs) • Reduction of 447 tonnes greenhouse gases per year

  5. Dozer Alternative Cabin Cooling System • No ‘off the shelf’ solution available for dozers • Expressions of interest sought from companies who could design, manufacture & install a system – initial trial of 3 machines • Main criteria were:- • No additional equipment inside the dozer cabin • Only one cooling system • Seamless changeover from when the engine was running to engine stopped

  6. Dozer Alternative Cabin Cooling System • System to run for minimum of 1 hour while engine stopped • Cabin must be kept as cool as existing system • Must be able to be fitted to all of the dozer fleet • No equipment to protrude higher than the coal canopy • No increase in noise or vibration levels for the operator

  7. Dozer Alternative Cabin Cooling System • Briskair (Brisbane based company) selected as partner for design, manufacture & installation • Two possible solutions – small diesel powered unit or electrically driven unit • Electrically driven unit selected due to local conditions - dust • operating angle • moisture from dust suppression & rain events

  8. Dozer Alternative Cabin Cooling System Batteries Alternator Alternator Air Conditioning Compressors Dozer Engine Batteries Condenser Evaporator Starter motors Engine Starting System Dozer Cabin Cooling System

  9. Dozer Alternative Cabin Cooling System Employee communication & update briefing aids

  10. Dozer Alternative Cabin Cooling System System Roof Mounted Control Box In Cabin Condenser Under Rear Of Coal Canopy

  11. Dozer Alternative Cabin Cooling System Prototype 1 – Compressors, electrical controls, minus batteries

  12. Dozer Alternative Cabin Cooling System Electrical Controls Batteries Compressors Prototype 2 – Compressors, batteries & electrical controls relocated & separated for ease of maintenance. Condenser no change of location.

  13. Dozer Alternative Cabin Cooling System Better mounted compressors Separate mounted electrical controls cabinet Batteries mounted in standard dozer chamber

  14. Dozer Alternative Cabin Cooling System • Prototype 2 system reasonably reliable over the summer period • Decision to be made re expanding the number of units installed • Monitor the reduction in idle time • Thanks to the Gladstone Ports Corporation & Briskair management & personnel for courage & vision to support this project • Benefit to Gladstone Ports Corporation & Australia in reducing energy consumption & lowering greenhouse emissions

  15. Issues & Lessons Learnt During The Project • Change in work practices – switch off engine don’t idle • Belief that idling the engine doesn’t harm the engine • Switching off the engine & restarting causes more harm & wears out starter motors • Some negativity from maintenance personnel during development • Don’t underestimate the resistance to change to operational & maintenance practices

  16. Issues & Lessons Learnt During The Project • Ensure the project has a champion who is there for the long haul • Try & keep employees involved with the suppliers in the design, manufacture, installation & maintenance of the system • A small capital outlay can result in significant return on that investment

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