Electric Mining Equipment

Mining equipment is among the most energy-intensive machinery in operation, traditionally powered by large diesel engines. Electrification in mining reduces fuel costs, improves worker safety by eliminating diesel emissions underground, and lowers ventilation requirements in tunnels and shafts. Surface mining equipment also benefits from reduced noise, higher efficiency, and integration with renewable-powered microgrids. Adoption is most advanced in underground loaders and trucks, with surface haul trucks and drilling rigs now entering pilot projects worldwide.

Electrifying haul trucks, loaders, and shovels is one of the highest-impact decarbonization benchmarks in the mining sector. These systems offer 50–100% reductions in Scope 1 emissions and major operational cost savings. Solutions exist to convert existing diesel trucks with battery modules.

Segment Taxonomy

The table below outlines major categories of mining equipment and their electrification pathways.

Spotlight: Underground Equipment

Underground mining is leading electrification due to safety and ventilation advantages. Diesel engines create toxic emissions that require costly ventilation, while electric loaders and haul trucks eliminate this burden. Battery-electric units can be swapped quickly and reduce operating costs over diesel. Key points:

• LHDs (load-haul-dump) are widely deployed in Canada, Europe, and Australia
• Battery swapping is standard to keep machines in operation without downtime
• Eliminating diesel cuts ventilation energy needs by up to 40%
• Lower noise improves working conditions and safety underground

Spotlight: Surface Haul Trucks

Electrification of ultra-class haul trucks in open-pit mines represents one of the biggest challenges due to their enormous energy requirements. Hybrid-electric, trolley-assist, and hydrogen-electric solutions are currently favored, though battery-electric retrofits are advancing. Key points:

• Komatsu and Caterpillar developing large battery-electric haul trucks
• Anglo American operating a 2 MW hydrogen-electric haul truck prototype in South Africa
• Trolley-assist systems (overhead catenary) reduce fuel consumption on uphill hauls
• Battery-electric feasible for shorter routes and dedicated operations

Electric Mining Equipment Vendors

Technology Stack

Mining electrification requires high-capacity energy systems and ruggedized components designed for heavy-duty cycles and harsh environments. The table below summarizes the key stack layers.

Charging & Energy Considerations

Mining operations often occur in remote areas with limited grid access, making energy supply a critical issue. Solutions include on-site microgrids, renewable integration, hybrid gensets, and battery-swapping depots. Underground equipment relies heavily on swappable packs, while surface haul trucks may use trolley-assist lines or megawatt-scale charging.

Market Outlook

Electrification of mining equipment is driven by safety, ventilation cost savings, and sustainability targets from major mining firms. Underground equipment is leading adoption, followed by surface haul truck pilots. The table below ranks adoption segments.

Industrial Impact

• Primary emissions reduction: Haul trucks account for ~90% of vehicular emissions at mine sites—BEVs directly target largest emission source.
• Opex reduction: Electric haul trucks can save >US $5.5 M in energy costs over life, reduce fuel costs by 30–60%, and cut maintenance by 20–50%.
• Safety & environment: Elimination of diesel exhaust reduces PM and NOx; noise drops by ~70%.
• Downtime & asset utilization: Electric drivetrains are simpler, requiring fewer oil changes and components, resulting in higher uptime and lower spare parts inventory.

Emissions Impact

• Per-truck reductions: Up to 500 t CO2e/year eliminated per converted haul truck
• Fleet-level impact: Replacing 360 trucks cuts 450 million liters of diesel and removes ~51% of Fortescue’s Scope 1 emissions.
• Health benefits: Diesel elimination improves air quality in confined mine environments.

Challenges

• Battery capacity and cost: Haul trucks require 1–2 MWh batteries; replacements may be needed 5+ times over lifecycle.
• Charging infrastructure: High-power (1–5 MW+) charging stations are necessary to maintain uptime; grid capacity can be a constraint.
• Battery safety & tenure: Fire risk and thermal management must be addressed, especially underground

Broader Mining Fleet Transition

Electrification of mining equipment is part of a larger shift toward sustainable and net-zero mining. Mining companies face mounting pressure from governments, investors, and downstream customers (such as EV and battery manufacturers) to decarbonize their operations. Fleet transition involves a combination of electrification, hybrid systems, renewable power integration, and digital fleet optimization.