Energy-Efficient Hybrid Technology for Bentonite Mining

Clariant reduces fuel consumption in open-pit mining by integrating a hybrid excavator and new dumpers from Volvo CE.  www.volvoce.com In resource extraction and mining, companies rely on energy-efficient hybrid excavators and robust transport fleets to reduce operating costs in open-pit mining and ensure occupational safety during heavy earthmoving operations. Activity and Operational Challenges The specialty chemicals company Clariant extracts bentonite from the ground in several open-pit mines between Mainburg, Moosburg, and Landshut. To expose the clay rock, which is valued for its high swelling capacity, large quantities of overburden typically need to be moved. Since the machines must flexibly switch between different pits due to weather conditions or depending on the required material quality, the equipment used is subject to strict transport dimensions and must maintain high mobility. Improvement Goals The primary goals of the project included significantly reducing fuel consumption during the constantly recurring movements in material extraction. In addition, extraction efficiency was to be increased by reaching material at greater depths without having to create additional intermediate steps. Another goal was to improve ergonomics and occupational safety for the driving personnel to maintain concentration during long shifts. Selected Technical Solution To achieve these goals, Clariant integrated an EC400 hybrid crawler excavator and five A40 articulated haulers (dumpers) from Volvo CE. The excavator's hybrid system stores the energy recovered when lowering the boom and uses it for the next work step. The excavator also features an extended boom for a greater depth reach and strictly adheres to the required transport width of 3.50 meters. For the transport of overburden, the new A40 generation dumpers were selected, which are characterized by optimized suspension, improved lighting, and an ergonomic driver's cabin. Deployment and Support The implementation and maintenance of the entire machine fleet are carried out under a full-service contract by the retail partner Robert Aebi. This service package covers extended warranties, customer service, and maintenance for a lease term of three to five years. In addition, the machines are monitored via a telematics system that continuously records operating data such as fuel consumption, overburden volumes, and operating hours. This enables the predictive planning of service deployments and ensures long-term operational readiness. Measurable Results By switching to hybrid technology, fuel consumption during material extraction has been reduced by approximately 30% in operations to date, which significantly lowers operating costs. The extended boom of the excavator allows for safe mining from above and reaches deep into the deposit, eliminating the time-consuming construction of intermediate steps. At the same time, the improved cabin ergonomics and suspension of the dumpers lead to noticeably less driver fatigue, enabling more concentrated and productive work on a daily basis. Written by Maria Brueva, Induportals Editor – adapted by AI. www.volvoce.com Powered by Induportals Media Publishing