BHP, Rio Tinto on fast track with electric haul trucks

Australia

PILBARA, May 28, 2024 – Mining giants BHP and Rio Tinto will collaborate to fast-track trials of electric haul trucks, the two companies announced on Monday.

The trucks, built by Komatsu and Caterpillar, will be trialled at large-scale iron ore mines in Western Australia’s Pilbara region.

Ongoing testing, development and refinement of truck and battery design is anticipated with each manufacturer, the companies said.

Rio Tinto’s iron ore CEO, Simon Trott, hailed the collaboration as “bring[ing] together two leading global miners with two of the world’s biggest manufacturers of haul trucks to work on solving the critical challenge of zero-emissions haulage.”

“Testing two types of battery-electric haul trucks in Pilbara conditions will provide better data, and by combining our efforts with BHP we will accelerate learning,” he said.

Meanwhile, BHP president for Australia Geraldine Slattery said replacing diesel fuel would require “a whole new operational ecosystem to surround the fleet.”

“We need to address the way we plan our mines, operate our haulage networks, and consider the additional safety and operational considerations that these changes will bring.”

Report finds almost 50% of mining vehicles

 to be electric by 2044

28 MAY, 2024
WRITTEN BY Aaliyah Rogan

Ahead of World Environment Day on 5 June, IDTechEx’s report, Electric Vehicles in Mining 2024-2044: Technologies, Players, and Forecasts, reveals that nearly 50% of mining vehicle sales will be electric vehicles (EV) by 2044.

The report forecasts the electric mining vehicle market will grow to more than US$23 billion ($34.66 billion) within 20 years, representing a 32% compound annual growth rate.

IDTechEx says the electrification of haul trucks will be key to achieving meaningful emissions reductions in the industry and supporting mining companies to meet sustainability targets.

While the electric mining vehicle market is still in its early stages, many mining companies have shown a willingness to adopt EVs.

Mining giant BHP (ASX:BHP) revealed today that it is collaborating with Rio Tinto (ASX:RIO) on battery-electric haul truck trials in the Pilbara region of Western Australia.

IDTechEx reports that haul trucks are among the most critical assets on any mine and currently emit 174 megatonnes of carbon dioxide per year.

The collaboration, alongside manufacturers Caterpillar and Komatsu, supports both companies’ shared ambition of net zero operational greenhouse gas emissions by 2050.

As part of the collaboration, two CAT 793 haul trucks will be tested in the second half of 2024, while two Komatsu 930 haul trucks will be tested from 2026 at mine sites in the Pilbara region.

BHP President Geraldine Slattery says replacing diesel as a fuel source requires the sector to develop a new operational ecosystem to surround the fleet.

“We need to address the way we plan our mines, operate our haulage networks, and consider the additional safety and operational considerations that these changes will bring,” she says.

“This is why trials are so critical to our success as we test and learn how these new technologies could work and integrate into our mines.”

Rio Tinto Iron Ore CEO Simon Trott says there is no clear path to net zero without zero-emissions haulage, as such, it is critical to work together and get there as quickly and efficiently as possible.

“As we work to repower our Pilbara operations with renewable energy, collaborations like this move us closer to solving the shared challenge of decarbonising our operations and meeting our net zero commitments,” he says.

According to IDTechEx, the mining industry accounts for 2% to 3% of all global CO2 emissions, with 40% to 50% of this coming from diesel combustion engines of mining vehicles.

Mining vehicles have a wide variety of duties, however, the most intense of those can require operating for up to 20 hours a day. As a result, a lot of diesel is consumed in the process, which is more expensive than electricity and subject to considerable price volatility.

IDTechEx’s analysis reveals that a single 150-tonne haul truck requires more than US$850,000 per year in fuel, while electrification can save more than US$5.5 million in energy costs over the vehicle’s lifetime.

Write to Aaliyah Rogan at Mining.com.au


Electric mining vehicle industry’s value to reach $23 billion by 2044

The electric mining vehicle industry is expected to be valued at nearly $23 billion by 2044, according to a new report by IDTechEx.

The analysis points out that large EV batteries and innovative fast-charging methods are driving the adoption of electric and autonomous mining vehicles.

“Mining vehicles come in a wide range of sizes so mining batteries can vary wildly too – from 100 kWh for light vehicles up to 2 MWh for large electric haul trucks. The uniquely large nature of these batteries means they are only now becoming sufficiently developed and competitively priced,” the report reads. “Turnkey battery suppliers, including CATL, ABB, and Northvolt, have developed products that are particularly well-suited to mining vehicles, and their development work is continuing.”

The document notes that lithium-nickel-manganese-cobalt or NMC and lithium-iron-phosphate or LFP batteries are the two battery chemistries that have, so far, been used in mining. In detail, just under 80% of mining vehicles use LFP despite such batteries’ tendency to have lower energy densities, which is not a major concern as mining vehicles are typically already heavy and carry hefty loads of ore.

“Where LFP does win out is in its cycle life. IDTechEx expects that some of the most demanding mining vehicles, such as haul trucks, will far exceed the cycle life deliverable by a single NMC or LFP pack and require multiple battery replacements. Minimizing the frequency of replacements by using a longer-life battery pack is an effective way to make EVs more economical,” the dossier notes. “Safety is another crucial factor in mining, especially regarding the fire safety of batteries in underground tunnels. LFP cells are generally considered safer in this aspect, which limits the risk posed to mine workers.”

Looking beyond NMC and LFP, IDTechEx expects more battery technologies such as lithium-titanium-oxide or LTO and sodium-ion or Na-ion to continue developing and eventually see viability for mining vehicles.

Tackling charging challenges

IDTechEx’s report emphasizes that one of the things that has slowed down the adoption of EVs in the mining industry is the multiple hours of downtime that they are subjected to while charging, a situation that hinders vehicle productivity.

However, the market analyst points out that original equipment manufacturers or OEMs have made some progress when it comes to bringing downtime closer to a level that mines are more familiar with.

“Conventional cable-based charging methods are used in many of these solutions, with most mining EVs utilizing DC fast charging. OEMs are now looking to employ methods including multi-gun charging and megawatt charging systems to bring times down to between 20 and 60 minutes,” the dossier states. “This goes some way to increasing the productivity of vehicles, but charging at such high rates can accelerate the degradation of batteries and increase the frequency of battery replacements.”

The analysis indicates that battery swapping is an alternative to cable-based charging, which has seen a lot of interest from mining OEMs, particularly for underground vehicles.

Battery swapping involves having two swappable battery packs per vehicle, one of which can be charged while the other is used in operation. Swapping can be done in dedicated swapping stations using a crane or hoist in as little as 5 to 10 minutes.

“Battery swapping is excellent for productivity but can be more expensive in some scenarios and will require dedicated space and infrastructure for swapping.”

Dynamic charging also plays a role in mining – vehicles can be charged in-cycle using power rails or overhead catenary lines along major pathways. This has the potential to eliminate charging downtime and maximize productivity, but it is still being developed and has seen the least use.

“All of the above charging methods are likely to play a part in driving the electrification of the industry, with different methods to be used for different vehicles depending on their technical requirements and duty cycle demands,” the document reads. “OEMs and charging providers are still working on optimizing their technologies.”