MATERIALS HANDLING
MOBILE MATERIALS MANAGEMENT
Exploring the advantages and infrastructure requirements of all-electric operation of mobile crushing and screening plants
Interlinked Kleemann plant train with an external power supply option M
obile crushing and screening plants that are operated with electricity instead of diesel
fuel are regarded as particularly environmentally friendly because they do not emit CO2
on site. They
are also ahead in terms of cost- eff ectiveness in the long term. Sustainable, low-emission solutions are in demand, and companies can position themselves on the market as future-oriented providers with electrically operated mobile plants. Although the initial investment costs are higher, they are quickly amortised due to the fuel savings. “Our mobile plant train in the
sample calculation consists of a jaw crusher Mobicat MC 120 Pro, cone crusher Mobicone MCO 110 Pro as a secondary crusher and a downstream screen machine Mobiscreen MSC 953 Evo. The plant train consumes an average of approximately 77 litres of diesel per operating hour. In the electrifi ed version, it has an average current consumption of 302kW per operating hour. The maximum power requirement is 542kw“, says Tobias Böckle, head of Product Management at Kleemann. “The energy requirement must fi rst be provided by the infrastructure and is ideally met by electricity from renewable sources. A sustainable and quickly cost-eff icient solution is to use an in-house photovoltaic power supply,” says the expert. A suitable design of the
infrastructure in advance is of decisive important for eff icient use.
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Tobias Möß from Wolff & Müller explains: “First of all, the actual energy requirements of the plant and the demand of all already existing consumers should be determined. How much power is needed on the entire company premises? The load profi le must also be taken into account. When are the power peaks, when are the times with lower consumption?” Möß adds: “The individual load profi le can be obtained from the energy supplier or network operator. Many companies already have a transformer on their premises that adapts the voltage to requirements and, for example, provides low voltage for systems. Once the required power has been calculated, it is necessary to check whether the available transformer is suff iciently dimensioned. Does it deliver the required power? The amount of power that can be drawn from the transformer is indicated on the type plate.” It is also important to consider
where the main distribution is located on the site and where the system will be used. Good planning here is a precondition for eff icient operation. For example, the electrical energy required to supply the plant is not transformed to low voltage directly at the transfer station, but is instead routed over the medium-voltage level across the site to the plant – the cable cross-section can therefore be much thinner, making the cable easier to handle and signifi cantly cheaper. At the mobile plant, a second
transformer converts the current into low voltage to operate the
mobile crushing or screening plant. The aim here is to develop a suitable individual concept.
RAPID ROI With a solid foundation, the investment costs are amortised after around six years – or even sooner, depending on the energy concept. From this point on, all- electric operation will save considerable operating costs year after year. Here is an overview of the switch
to electricity as an example: with the diesel-powered plant, there is no need for additional investment in the infrastructure apart from the fuel costs. The cost of diesel fuel varies greatly depending on the country and region, so any savings depend on the diff erence in price between diesel and electricity. Electrically operated crushing
and screening plants are initially more expensive due to their special equipment, plus the cost of cables (depending on the length of cable required) and a transformer. All-electric operation incurs initial
investment costs, but these pay off in the medium term. In many cases, climate protection regulations lead to stricter requirements. The electric drive is a decisive advantage, for example, when local authorities demand emission-free operation in city centres. “Especially in combination with your own PV system, electrical operation becomes a climate- friendly, cost-eff icient concept in just a few years, which not only provides the operating company with fi nancial benefi ts, but also refl ects the company’s eff orts to achieve greater sustainability,” Tobias Böckle is convinced.
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