Project Objectives

  • Develop a zero-emissions fuelcell-powered mine loader equivalent to a Caterpillar-Elphinstone R1300 or larger loader.
  • Develop a refueling system based on electrolysis of water.
  • Evaluate safety and productivity of the system at a mine in Nevada.

 

Project Overview

Sponsor: U.S. Department of Energy (DOE), Golden Field Office, Golden, Colorado

Period of Performance: 3 1/2 years (March 2002 through August 2005)

Total Cost: Estimated US$7.6 million

 

Phase 1: Feasibility Analysis, Preliminary Engineering Design, and Refueling-System Development

Period of Performance: 1 year (March 2002 through February 2003)

Cost: US$1.2 million

Funding Sources:
US$613,500 – U.S. Department of Energy (DOE)
US$260,000 – Natural Resources Canada (NRCan)
US$353,500 – Cost share by industrial partners

Partners:
Caterpillar Elphinstone – Vehicle design
Fuelcell Propulsion Institute – Industry oversight and education
Mine Safety and Health Administration – Risk evaluation of system
Natural Resources Canada – Feasibility analysis
Newmont Mining Corporation – Evaluation of refueling system
Southwest Research Institute – Simulation modeling of powerplant
Stuart Energy Systems Inc – Development of refueling system
University of Nevada at Reno – Surface testing in Nevada
Vehicle Projects LLC – Prime contractor and project management
Westinghouse Savannah River Company – Metal-hydride design

 

Phase 2: Detailed Engineering Design

Period of Performance: 1 year (March 2003 through February 2004)

Cost: US$3.3 million

Funding Sources:
US$1,643,709 – U.S. Department of Energy (DOE)
US$150,000 – Natural Resources Canada (NRCan)
US$75,000 – Placer Dome Technical Services
US$1,418,709 – Cost share by industrial partners

Partners:
AeroVironment – Balance-of-plant design
Carleton University – Software modeling
Caterpillar – Drivetrain and system integration design
Caterpillar Elphinstone – Provide R1300 base vehicle
Fuelcell Propulsion Institute – Industry oversight and education
HERA Hydrogen Storage Systems – Metal-hydride storage design
Mine Safety and Health Administration – Risk evaluation of system
Natural Resources Canada – Design support and long-term testing
Newmont Mining Corporation – Industry oversight
Nuvera Fuel Cells – Fuelcell stack manufacturer
Placer Dome Technical Services – Industry oversight
Vehicle Projects LLC – Prime contractor and project management

Milestones:
1 March 2003 – Start date
July 2003 – Specifications and requirements complete
August 2003 – Design review
September 2003 – Receive fuelcell stacks
February 2004 – Detailed design complete

Powerplant Packaging:

 

Phase 3: Powerplant Fabrication and System Integration

Period of Performance: 1 year (March 2004 through February 2005)

Cost: Estimated US$2.1 million

 

Phase 4: Safety and Productivity Evaluation at a Mine in Nevada

Period of Performance: 6 months (March 2005 through August 2005)

Cost: Estimated US$1 million

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