Electrifying Mining with EVs and Automation - ABB's Guide
Mining is a word that can have negative connotations. However, ABB is embedding electrification in the industry to change this.
Its latest whitepaper, Building the All-Electric Mine, is a roadmap for mining companies and their suppliers to transform the industry’s reputation. ABB has demonstrated that electrification significantly reduces emissions while enhancing operational output.
From haul trucks and loading equipment to conveyors, the industry can now electrify essential machinery. Every site can take steps towards an “all-electric mine”, where small, smart shifts deliver significant performance gains. This transition is critical because the industry accounts for 7% of greenhouse gases globally, making the move to electric power essential for sustainable operations.
Supply chains for a low-carbon future
The whitepaper notes that the industry must collaborate to supply necessary materials for a low-carbon future, such as lithium for electric vehicles and rare earth elements for wind turbines.
According to ABB, mining teams will experience minimal disruption during this transition, gradually accumulating carbon and financial savings. Research indicates that 53% of mining leaders expect their operations to transform over the next five years.
While rising costs and falling commodity prices have squeezed the industry recently, electrification has progressed significantly. ABB has been commissioned to conduct 26 studies across nine countries since 2021, providing blueprints for progress and building confidence.
Currently, 42% of companies plan haulage decarbonisation investment by 2026, and 68% plan to electrify 25% of fleets by 2030.
Performance gains with electric haulage fleets
Sustainability arguments are strengthened when they include increased profits and enhanced safety. ABB states that electric trucks tick all the boxes. They are twice as fast as diesel equivalents, significantly boosting productivity, and have fewer moving parts, leading to reduced maintenance and downtimes.
These vehicles can be charged without human intervention and reduce harmful pollutants and noise levels, particularly in underground mines. When trucks and connected devices are autonomous, personnel no longer have to carry out dangerous tasks.
To achieve this, ABB supports partnerships with original equipment manufacturers, providing onboard equipment such as batteries and inverters. This allows mining teams to retrofit diesel trucks to reduce emissions, improve safety, boost productivity and lower the overall operating costs.
Stationary and dynamic energy transfer solutions
For large haul trucks to be electrified, mines require a combination of stationary and dynamic energy transfer solutions. Mapping mine constraints, such as loading areas and power availability, is essential for implementation.
Stationary systems allow for charging while trucks are still, using manual or automated connection devices. Fast offboard systems are ideal for trucks in continuous operation, while slow onboard systems suit equipment like drill rigs.
ABB also highlights trolley-assist systems as a dynamic charging solution, feeding power into diesel-electric trucks through overhead lines. In collaboration with Epiroc, ABB deployed the first fully battery-electric trolley truck system on an underground test track for Boliden. This 5km segment recovers energy through regenerative braking on downhill sections.
Synergy between automation and electric power
Automation and electrification are mutually beneficial. Control platforms integrate power and process control to manage variable loads.
ABB says that automated energy management systems analyse operational schedules in real time, allocating power where it is needed. This technological shift is also a significant draw for younger workers.
With an ageing workforce, mines that do not adapt may struggle to attract talent. More than two-thirds of respondents see technology as a driver for diversity and a way to attract Gen Z.
Digitalisation and automation show that modern mines are sophisticated environments, fundamentally changing negative perceptions. The absence of diesel fumes means better air quality and healthier workers, while electric systems reduce fire risks and vibration, resulting in fewer accidents.
