With just two months to go until The Electric Mine 2025 in Santiago, Chile, being held May 13-15 at Centro Parque in Las Condes, it is a useful exercise to review again some of the learnings and knowledge shared at The Electric Mine 2024 in Perth, Australia.
The Global Mining Guidelines Group (GMG) was an official partner for the 2024 event, which included attendance by Theresa Rogers, GMG Communications Manager & Editor-in-Chief, along with Devi Kumaran, Consultant at Via Novus Consulting. The following is a detailed report they put together, which is a great stepping stone to the forthcoming Chile event. It includes some of the presentation highlights – with many of these companies also part of the 2025 lineup.
The mining industry is in the midst of a profound transformation as it embraces electrification. Traditionally reliant on fossil fuels, mining operations are increasingly turning to electric technologies to power equipment, vehicles, and processes. This shift is driven by the growing need to reduce greenhouse gas emissions, enhance operational efficiency and safety, and meet stringent environmental regulations. Electric mining offers a pathway to a more sustainable and cost-effective future, where energy consumption is optimised, and the environmental impact is minimised.
As global demand for minerals and metals continues to rise, the industry faces the dual challenge of increasing production while reducing its carbon footprint. Electrification presents a compelling solution, offering not only the potential for significant reductions in emissions but also improvements in safety, productivity, and overall operational performance. From electric haul trucks and drills to renewable energy-powered processing plants, the integration of electric technologies is reshaping the industry landscape.
Nowhere was this more apparent than at The Electric Mine 2024 conference, which took place in Perth, Western Australia, in May last year. More than 900 industry leaders came together over three days to explore the current state of electric mining, examining the technologies, trends, and challenges shaping its adoption. Presenters delved into the benefits of electrification, the barriers that must be overcome, and the strategies industry leaders are employing to transition to a more electric future. By embracing electrification, the mining sector can pave the way for a more resilient and sustainable industry, one that is better equipped to meet the demands of the modern world while safeguarding the environment.
Call to Action
With fast-approaching global sustainability goals, miners must act now to develop their sustainability plans without limitations of infrastructure or cost. According to the ICMM, diesel-powered mining vehicles account for 30 to 80% of direct emissions at a mine site, depending on the site geography and commodity being mined so it’s no wonder electrification of fleets, mine planning and renewable energy are key strategies in achieving carbon reduction goals. All miners can leverage the advantage of effectively using their fleet management system (FMS) and mine planning tools to run mining simulations for carbon emissions and energy, crucial for the transition. As miners strive to reduce greenhouse gas emissions, alternative energy sources such as wind, solar and hydrogen are imperative. Solutions to decarbonise the majority of emissions will become economical within this decade, addressing both Scope 1 and Scope 2 emissions.
The mining industry benefits from a new generation of lower emission and sometimes driverless mine vehicles that are transforming the image of the industry. Electric vehicles (EVs), for use in both open pit and underground operations, are added to fleets either through purchase or by the retrofit of existing diesel engine vehicle fleets. Electrification is advancing in underground projects faster than open pits, but both are a focus today and will become even more so in the 2030s.
Benefits of Electrification
There are many benefits of transitioning to electric mines including higher efficiency, and reduced capital expenditures, maintenance costs, wear and tear and operational expenditures.
The total cost of ownership of battery electric vehicles for mining could be approximately 15 to 20 % lower than diesel trucks due to lower maintenance and fuel costs, says McKinsey & Company, which estimates that by 2030, the total cost of ownership (TCO) for BEVs or hydrogen fuel cell electric vehicles (FCEVs) in mining could be approximately 20% and 10% lower than existing diesel trucks, respectively. This projection accounts for 20% to 30% lower maintenance costs and 40% to 60% lower fuel costs, despite higher upfront vehicle and infrastructure expenses.
While diesel trucks are the greatest source of carbon emissions in surface mines, underground mining is showing great interest in the concept of battery electric vehicles because of the more immediate benefits of reduced emissions, improved ventilation, and lower ambient temperature.
Challenges
The challenges of sourcing materials needed for batteries and other sustainable technologies are increasingly complex. As the global demand for electric vehicles, renewable energy storage, and other green technologies rises, so does the need for critical minerals such as lithium and cobalt. These materials, however, are often found in limited, geographically constrained deposits, leading to supply chain vulnerabilities. Mining companies face the difficult task of balancing the urgent demand for these materials with the need to implement sustainable and responsible mining practices that minimise environmental impact and ensure ethical sourcing. The race to secure these resources is further complicated by the lengthy and capital-intensive nature of mining projects, as well as regulatory hurdles and the evolving landscape of global trade policies. The irony is not lost on most that mining companies are competing for products using the very materials they are extracting.
“The final challenge I see for our sector is the traditional path we have taken to where we are today where everyone has decided to go it alone,” said Adrian Beer, former CEO of METS Ignited, speaking directly to miners. “I love the word, ‘collaboration;’ everyone talks about it all the time… what we need to do as an industry is not try to go it ourselves but start to aggregate big challenges facing groups of companies to make it attractive to vendors to see the problem and to give researchers direction on where they need to find new knowledge – we need to see this from a market-serving perspective.”
Conference Highlights
Cavotec: Transforming Mining Fleets with the Megawatt Charging System
Cavotec’s Megawatt Charging System (MCS) is designed to meet the growing demand for rapid, high-power charging of heavy-duty BEVs. Traditional charging systems for electric vehicles in mining are often limited by their power output, resulting in longer charging times and reduced productivity. Cavotec’s MCS addresses this challenge by delivering charging power in the megawatt range, enabling BEVs to be charged rapidly and efficiently, minimizing downtime and maximising fleet availability. Any charging solution must be a holistic one, said Jim Andriotis, Chief Technology Officer, Cavotec. “It’s about equipment availability. If you can’t charge your Tesla in the evening, you can go find a supercharger and plug it in. If you can’t charge your haul truck during a cycle, you’re really buggered.”
Reliability of charging equipment must meet 99.9% availability. Installations must also be suited to extreme environments and remote or small locations. One of the key features of Cavotec’s Megawatt Charging System is its ability to provide ultra-fast charging for large electric vehicles, such as haul trucks, loaders, and drills, integral to mining operations. The system is designed to handle the high energy demands of these vehicles, significantly reducing the time needed to recharge their batteries compared to conventional systems. This rapid charging capability is essential for maintaining the round-the-clock operations typical of mining, where any downtime can result in significant operational costs.
Fortescue – Leading the Way in Decarbonisation
Fortescue, one of the world’s largest iron ore producers, has committed to achieving net zero emissions across its operations by 2030. Fortescue’s decarbonisation strategy is driven by a vision to reduce its carbon footprint and lead the mining industry in sustainability. This goal is underpinned by substantial investments in renewable energy, innovative technologies, and a complete transformation of its operational practices.
“The first part of solving any problem is admitting a problem exists,” said Meheroop Chopra, Head of Green Power, Fortescue. “This is the reason why we are diversifying our business into green technology, green energy and green metals. Our aim is to supply the world with the green solutions it needs to decarbonise today because the only way we can manage climate change is to stop using fossil fuels now.”
A cornerstone of Fortescue’s decarbonisation efforts is its transition to renewable energy sources. The company is investing heavily in solar and wind projects to replace its reliance on diesel and gas for power generation. One of the flagship projects is the Pilbara Energy Connect program, which integrates large-scale solar power with battery storage to provide a stable and sustainable energy supply for Fortescue’s mining operations in Western Australia. This shift not only reduces greenhouse gas emissions but also lowers operational costs in the long term.
Fortescue is also leading the charge in electrifying its mining operations, including the introduction of BEVs and hydrogen fuel cell technology. The company has launched several initiatives aimed at replacing its diesel-powered fleet with electric alternatives, significantly reducing emissions associated with transportation and machinery. In 2021, Fortescue unveiled its first hydrogen-powered haul truck, a critical step in its journey toward a fully electrified and sustainable mining fleet.
Fortescue’s decarbonisation strategy is bolstered by strategic partnerships and collaborations with leading technology providers, governments, and research institutions. These partnerships are essential for advancing innovative solutions and scaling up green technologies. Fortescue’s influence extends beyond its own operations as it advocates for global action on climate change, participating in international forums and sharing its expertise to help other industries reduce their carbon footprints.
Fortescue’s comprehensive approach to decarbonisation is already yielding significant results. The company has made substantial progress in reducing its Scope 1 and Scope 2 emissions.
“We are fully committed to our Real Zero target which means we will run our operations when the sun is shing or the wind is blowing and we have stored enough energy in our batteries or green molecules,” Chopra said. “This also means we will either turn down or turn off operations when renewable energy isn’t available. We call this Demand Response. It will be a world-first for heavy industry of this scale in our iron ore business.”
Caterpillar – wider electrification readiness
The wider electrical readiness issue was also addressed by Sean McGinnis, Caterpillar VP and General Manager, Resource Industries who said no matter where the mine is located, the single most important thing the industry needs to enable electrification is the modernisation and stabilisation of the electrical grid.
“The amount of demands we are going to put on that grid or the addition of that grid or expansion…is going to be pretty substantial,” he said. “Our reciprocating engines and gas turbines today play a major part in what I believe is an alternative fuel to enable this and that is natural gas. We use those to produce that natural gas and also to distribute it. We also use those same reciprocating engines and gas turbines as we continue to get more and more renewable power sources whether it is solar or otherwise and that creates a distributing grid to provide grid stability.”
The Role of Modeling and Mine Simulation in Mine Electrification
As the mining industry transitions toward electrification, the use of modelling and mine simulation are indispensable tools for mining companies pursuing electrification. By providing a detailed, risk-free environment to design, test, and optimise electric systems, these technologies can help make the transition to electric mining easier.
Adam Price, Product Manager, Simulation, RPMGlobal, presented a simulated all-electric mine using the company’s HAULSIM software. “It’s the only code-free discreet event simulation software built for the mining industry, allowing users to create their own models and run simulations in a fraction of the time of other options,” he said.
Stressing the software is a haulage simulation tool, not a scheduling package, Price took the audience through the running of the mine and the various parameters used. Everything is configurable from trolley charging performance to the type of fleet (electric, hybrid, etc) to the various truck config characteristics.
“In an all-electric mine, the reliability of the electrical charging infrastructure will be paramount,” said Price. “Each operation will have to balance the cost of having a robust system with redundancy against losses in productivity if redundancy is not built in. The modelling presented here also shows that the system will need to be able to respond ot large fluctuations in electrical demand as trucks move in and out of charging infrastructure. If this is not understood at the design stage, it may lead to the kind of faults that you are describing.”
Peter Brady, Principal Application Engineer, MathWorks, says simulation is an important collaboration tool on the road to electrification. “I’m not here to sell you on electrification. I’m here to sell you on a methodology to investigate and a methodology collaborate with your OEMs and your mine designers and your CEO to design all the way through life of mine.”
He emphasised, “If you take one thing home from me today, it’s to push back on your OEMs, and on your contractors. Bring some expertise back in-house and think about how you’re going to design and evaluate yourselves.”
Key cited benefits of simulation in the context of mine electrification:
- Optimisation of Electric Infrastructure: By simulating various scenarios, mining companies can determine the most efficient layout for electric infrastructure, including the placement of charging stations, power distribution systems, and energy storage solutions. This helps in minimising energy losses, ensuring reliable power supply, and reducing operational costs.
- System Performance Evaluation: Simulation allows for the evaluation of different electric systems under varying operational conditions. Companies can model the performance of BEVs, trolley systems, and hybrid solutions to understand how they will perform in real-world scenarios. This is particularly useful for assessing the impact of electrification on productivity, energy consumption, and maintenance requirements.
- Risk Mitigation: By using simulation tools, mining companies can identify potential challenges and bottlenecks in the electrification process before they occur. This proactive approach allows for the development of contingency plans and adjustments to the design, minimising downtime and disruptions during the transition.
- Cost-Benefit Analysis: Simulation provides a detailed analysis of the costs and benefits associated with different electrification strategies. This includes comparing the long-term operational savings from reduced fuel consumption and maintenance against the upfront investment in electric technologies. Such insights are crucial for making informed decisions and securing stakeholder buy-in.
- Training and Workforce Development: Simulation models can also be used for training purposes, allowing operators and engineers to familiarise themselves with new electric systems in a virtual environment. This accelerates the learning curve and ensures that the workforce is prepared for the shift to electrified operations.
Retrofitting Diesel Equipment: Transitioning to Electric Power
The shift from diesel-powered to electric and battery electric represents a significant advancement in the mining industry’s journey toward sustainability. Retrofitting existing diesel equipment with electric systems is an increasingly viable strategy, allowing companies to modernise their fleets without the need for completely new machinery. This approach not only reduces greenhouse gas emissions but also enhances operational efficiency and reduces maintenance costs.
J. Balamurugan, Senior VP, Engineering and Technology at Indian contract mining major Thriveni knows with a large number of diesel machines still having significant residual life left, mine operators are faced with a difficult choice between continuing to use diesel machines or replacing perfectly functional machines with electric versions at huge capital cost. Thriveni tackled this problem at the Surjagrh mine in India by converting diesel-powered excavators to electric operation by retrofitting the prime mover with an electric motor. The results have been overwhelmingly positive, Balamurgugan said, and Thriveni is well on its way to complete conversion of around 10 of the 120-t, 250-t and 700-t class excavators into electric operation, making significant progress in the greening of its fleet and having the confidence to undertake other conversion activities.
Komatsu’s Martin Luckock, Oceania Sales and Business Support Manager, and Thomas Harsk, Business Development Manager, provided a detailed case study on converting a diesel-powered hydraulic mining excavator to tethered electric drive in a Zambian copper mine in 2019. The study highlighted the benefits of mid-life conversions, illustrating their potential to enhance efficiency and give equipment a second life.
Harsk also dug in deeper on a business case of a client retrofit in Canada citing a reduction in total cost of ownership as “30 to 50% cost-per-hour reduction by going electric.”
Benefits of Retrofitting
- Reduced Emissions: One of the most significant benefits is the reduction of greenhouse gas emissions, which is crucial for meeting environmental regulations and corporate sustainability goals.
- Lower Operating Costs: Electric powertrains generally have fewer moving parts than diesel engines, leading to lower maintenance requirements and longer intervals between service.
Improved Energy Efficiency: Electric systems are more energy-efficient than their diesel counterparts, resulting in reduced energy consumption and lower operational costs over time. - Enhanced Worker Safety: Battery electric systems reduce noise and vibration levels, creating a safer and more comfortable working environment for operators.
Despite the clear benefits, retrofitting diesel excavators to electric power comes with its own set of challenges. The upfront cost of retrofitting can be significant, though this is often offset by long-term savings in fuel and maintenance.
Haul Trucks & Trolley Assist
Fabiana Cavalcante, Global Head of Mobile e-Power, ABB, told the conference crowd Nuh Cement and ABB have completed a retrofit of a haul truck from diesel to zero emissions with fully electric propulsion. The conversion of Nuh Cement’s cement haul truck from diesel to a fully electric, zero carbon emission vehicle was a world first for a vehicle of this size and class.
The retrofit to electric propulsion will save approximately 100,000 litres of fuel and prevent 245 t of carbon dioxide emissions annually. The switch will significantly reduce operating costs of mining activities while boosting efficiency and performance. Retrofitting trucks is a viable, quick solution that mining operators can take advantage of as an immediate step toward meeting their ambitious sustainability targets.
Tomás Nass, Decarbonization Manager, Antofagasta Minerals and Ratna Kanth Dittakavi, Global eMine Sales Manager at ABB presented on the Los Pelambres trolley project which they are partnering on. Nass said: “The first step of the partnership was to build a trial that could help us understand the potential impacts of building a trolley line in one of the copper mines that we currently have operating in Chile. It’s important to say that there is not a single trolley line currently operating – and Antofagasta bought potentially the first one to ever be installed in the country – so the change management of that is going to be challenging in itself.”
As a test, the company installed almost one kilometre of trolley in one of the dump areas of Minera Los Pelambres. It was “basically to test out, are we really going to deliver the speeds that are expected; the road quality that we should expect out of the system to actually keep the truck plugged into the system. What’s the width – is it going to change, is it going to need a new mine design? What’s the time to construct all this? What’s the potential impact of moving it around?”
According to Nass, main roads in Chilean copper mines typically only last for about three years before being moved. The trolley line is expected to be operational in 2025.
Echion Technologies: Pioneering Innovative Battery Chemistry
Echion Technologies, a spin-out from the University of Cambridge, has emerged as a leader in the development of innovative battery chemistry, particularly in the realm of advanced anode materials. “Successful partnerships to decarbonize mining need great chemistry,” said Benjamin Ting, Chief Commercial Officer. “You can always come to us to learn about anything to do with batteries.”
Ting says Echion’s next-generation batteries offer improvements in energy density, charging speed, and safety compared to conventional lithium-ion batteries. At the core of Echion’s innovation is the development of niobium-based anode materials, which are poised to revolutionise the battery industry by addressing some of its most pressing challenges.
One of the key breakthroughs by Echion is the introduction of mixed niobium oxide (XNO) as an alternative to traditional graphite anodes. This material enables ultra-fast charging, allowing batteries to reach full charge in just a few minutes without compromising energy density or cycle life. Unlike traditional lithium-ion batteries, which suffer from safety risks such as thermal runaway, Echion’s XNO technology offers enhanced thermal stability, reducing the risk of overheating and making the batteries safer for high-power applications.
Hitachi Energy – Powering the Mine
Power demand is expected to double by 2050, and utilities are limited in capacity. Utilities in transmission, distribution, and generation are at the forefront of the shift toward low-carbon, efficient and sustainable energy.
For more than 60 years, sulphur hexafluoride (SF6) was used as an electrical insulator in substations. It is considered one of the most potent greenhouse gases, with a global warming potential 23,500 times greater than carbon dioxide. Following EU regulation, SF6 will be used after 2028. Enter Hitachi Energy with a GIS system made by EconiQ technology, which is SF6-free. The technology uses C4FN gas, oxygen and carbon dioxide which does not impact the environment and has a lower lifecycle assessment.
“Integrated GIS applications have a 90 per cent reduction in footprint, withstand corrosive environments, reduce project energisation lead time by 40%, lower risk in execution and 80% reduction in material required for substation manufacture,” said Luca Nucci, Global Business Development Manager IMP PGHV, Hitachi Energy.
Hitachi Energy integrated gas-insulated switchgear applications (IGA) communicate with the entire fleet and modular switch gear monitoring (MSM) architecture and is integrated in the substation to monitor and control all equipment and components. This maximises cost efficiency by monitoring and foreseeing maintenance requirements.
The lead time to deliver a substation is three months for design, seven months for manufacture and six weeks for a full turnkey subtransmission substation (up to 170 kW).
Other Key Conference Takeaways and Quick Wins
- Vendors, especially those new to mining, must meet with customers and truly understand the business and the goals. “Procurement is not where you start this journey,” said Adrian Beer, former CEO of METS Ignited. Very little innovation happens in procurement. Procurement happens once the innovation is completed and the business is comfortable with the investment decision it will make and then it wants to manage the risk to the supply of equipment.
- Mixed fleets require less infrastructure than all-electric fleets and are often the best way to get started. Begin with some battery electric equipment and use diesel equipment to fill the gaps.
- Order your electric fleet soon. At full production it will take OEMs 25 years to produce enough BEV haul trucks to replace the global fleet. (Day 1 Keynote: Paul Lucey, Principal of Mine Electrification & Technology, Worley)
- Just get started. “The easiest driver of collaboration is doing,” said Darren Kwok, Head of Mining Electrification and Technology, Perenti. “Get together in a room. The thing that drives us forward is answering questions and solving problems. You don’t have to start big, you don’t have to buy a fleet. Start with a feasibility study. Jump in on a single machine. There is a whole heap of opportunity to jump in. We’re beyond novelty, we need to advance electrification as a verb; we need to just do it. With these conversations, it starts to normalise electrification and once we normalise, the pickup rate will increase. My callout to the industry is get moving. Start.”
- Alternative material movement – bring the processing plant to the pit face if possible.
- Battery chemistry – be chemistry-agnostic. There is no need to buy the best or latest.
- Think systems integration and take all aspects of a business into account including change management, data integration, cyber security, transition to operation, infrastructure management, communications management, understanding hazards and risks, environmental factors, and system upgrade management.
Collaboration on Helps Industry Navigate Changes
At Global Mining Guidelines Group (GMG), industry collaboration on “the how” of electrification is helping industry navigate the changes.
The Electric Mine Working Group
A global community that aims to accelerate the adoption of all-electric technologies in mining, address the challenges associated with them, and share information on how they can enable safer, more efficient, productive, and cost-effective mines.
Recently Published
In June of 2022, Global Mining Guidelines Group (GMG) published Recommended Practices for Battery Electric Vehicles in Underground Mining – Version 3 . This guideline provides guidance and an overall discussion about the benefits, drawbacks, and planning requirements for designing and implementing a BEV fleet within an existing or new mine. The document includes expanded content on safety, risk, and emergency response, maintenance, and sections on automated connection interfaces.
Current GMG Projects
Electric Mobile Equipment KPIs and Data Sharing
This project arose with the recognition that the mining industry is shifting from traditional diesel-operated equipment to battery electric vehicles (BEVs). The shift toward electrification requires enhanced focus on electrical energy management relative to resources. As well, ensuring BEVs are operated in a cost-effective manner will require an alternative lens on operations, processes, and culture to optimise material movement. This white paper will offer KPIs that can help mining companies integrate BEVs into their operations while enabling improved decision-making and planning. A staged project approach will lead to data access and sharing, and benchmarking in the industry.
Implementation of Battery Electric Vehicles in Surface Mining
GMG’s Recommended Practices for Battery Electric Vehicles in Underground Mining – Version 3 is the playbook that helps mining companies focusing on BEVs within their underground operations reach their goals because it shares lessons learned, and tried and true practices found throughout the industry.
Now, with BEVs in surface mining operations a key focus of development by OEMs, with small-scale commercial trials underway for ultra-class battery trucks, the time is right to develop a surface-specific guideline. Surface mining has unique considerations that complicate the shift and implementation of battery electric equipment on the surface. This guideline will help address these challenges.
Topics will include:
- Operational Readiness
- Transition, Change Management and Business Case Creation
- Energy Management Requirements and Charging Infrastructure
- Fleet Management, and more
What is GMG?
GMG brings the global mining community together to facilitate and mobilise the sharing of knowledge, expertise, and experience to develop innovative guidance, resources, and common practices that can be operationalized in response to some of the industry’s most pressing needs.
- 5,700 Industry Leaders
- 140 Corporate Members
- 9 Working Groups dedicated to all facets of the industry including those especially impacted by electrification: Autonomous Mining, The Electric Mine, Data and Interoperability, and Sustainability
Chirag Sathe, Chair of GMG’s Autonomous Mining Working Group, and Principal Autonomy at BHP, also presented at The Electric Mine. His presentation, Integrating AHS and Electrification Through the Lens of System Safety, dealt with advancing safety-centric mining practices in an era of automation and sustainability.
System safety provides a holistic view – people, process, technology – he said. “Everybody is so busy with developing technology, they need to look at the end goal: how are we going to operate it?”
By seamlessly integrating AHS with electrified equipment, mining companies can mitigate risks associated with human error and traditional diesel-powered machinery. This integration optimises operations, reduces carbon footprint and enhances worker safety by minimising exposure to hazardous environments. Taking a system safety approach provides an overview of safety-related activities throughout a systems lifecycle and helps ensure risks related to adopting automation are minimised as much as practicable. The presentation emphasised the critical role of a holistic safety approach, wherein technological innovations are implemented within a framework that prioritises the well-being of both personnel and the environment.
Visit https://gmggroup.org for more information or email [email protected] to get involved.
