Projeto de um sistema de armazenamento de energia para caminhões de mineração híbridos considerando os perfis de missão e a degradação do banco de baterias

Abstract

The partial electrification of off-highway haul trucks in mining operations represents a promising pathway for reducing diesel consumption and associated emissions. However, it introduces significant technical and economic challenges related to the optimal sizing of battery energy storage systems. The central challenge lies in determining the battery pack capacity that balances capital investment, electrochemical degradation, and the economic benefits derived from regenerative energy recovery throughout the equipment’s operational life. This work proposes an integrated dynamic model for simulating state of charge evolution, cycle and calendar degradation, energy flow, and economic performance of a battery energy storage system applied to off-highway haul trucks. The methodology was evaluated using real operational profiles from Brazilian mining sites, representing distinct mission cycles and topographic conditions. The model incorporates rainflow cycle counting, empirical electrochemical aging equations, and a discounted total cost formulation over a 60-month horizon. The sizing problem is treated as a black-box optimization and solved using Bayesian optimization, which is suitable for nonlinear and computationally expensive objective functions. The results demonstrate that the operational profile has a decisive influence on both the optimal battery capacity and the overall economic feasibility of partial electrification. For the three real-world profiles analyzed, discounted total cost reductions of 14.62%, 54.39%, and 30.11% were achieved, respectively, when compared to a diesel-only baseline scenario. Profiles with higher regenerative energy potential exhibited greater economic attractiveness, even when multiple battery replacements were required within the analyzed horizon. Sensitivity analyses indicate that energy cost is the most influential parameter in the sizing process, while variations in the initial state of charge have marginal impact on the optimal solution. The findings reinforce that optimal battery sizing is not universal but strongly dependent on the specific energy characteristics of the mining operation, highlighting the importance of mission-specific modeling in fleet electrification strategies.