Chain Lift Rail System

The best optimized alternative to the open-pit mine haul truck system that will replace the existing diesel-powered fleet in 2030 would be to implement a rail system driven by an all-electric chain-lift system. This solution is Wabtec’s most achievable solution to meet their stated sustainability and environmental goals which include a zero-emission haulage fleet.
The implementation of this system would include both a continuous rail system running from the bottom of the mine to the refinement facility, as well as a connected system of mine carts driven by a chain lift system. This chain lift system, similar to what is seen in roller coasters, would be driven by a system of Wabtec’s FLXdrive 4400 hp locomotive motors adapted for this function.
First, the carts are loaded via a hopper at the bottom of the mine. After traveling up the grade via the chain lift system, the carts travel to the refinement facility. The carts have a dump door/chute on the side, as well as a hydraulic system to lift the cart to facilitate dumping. This system allows easy dumping of material out of the cart at the top of the mine. Both of these technologies allow for the carts to be loaded and unloaded without stopping.
This design allows for minimal wasted work during the transportation process. With the current system, trucks use a large portion of their power to move the powertrain and fuel source along with the load. With our design, both the powertrain and fuel source are stationary, resulting in a more efficient use of energy. Carts traveling down the grade not only use 0 energy to move, but actually add energy to the system by helping pull the loaded carts back up the grade.
Although the start-up costs of rail-based transportation are high, this system will result in much lower operating costs than the 400T mining trucks currently in operation. Not only does this system use less overall energy due to the decreased load and friction, but it also uses a cheaper source of energy: grid electricity. This, combined with decreased maintenance costs from an overall less complex system, allows for the rail system to quickly make up the difference of the implementation costs versus the 400T trucks.