- Study by IGO Limited, Perenti and ABB found it technically feasible to convert the Cosmos Nickel Project in Western Australia to an all-electric underground mine fleet
- Findings showed that battery electric vehicles comparable in size and performance to a diesel-based fleet are available at non-prohibitive CAPEX/OPEX
- The partners' proposed approach would result in significant safety and environmental benefits through reduced underground particulate emissions and lower greenhouse gas emissions
A collaboration between IGO Limited, Perenti and ABB has revealed that an all-electric underground mine fleet for the Cosmos Nickel Project in Western Australia would be competitive with diesel vehicles.
The Cosmos Underground Electrification Study found that battery electric vehicles (BEVs) could match the productivity of a planned diesel fleet at an estimated cost that would not be probibitive over the envisaged life of mine, even based on conservative productivity and cost assumptions. It also found that a BEV fleet would enable a significant reduction in cooling and ventilation demands compared to a diesel alternative, which would offset the additional power required by BEVs. Consequently, the estimated overall power balance of the electrified Cosmos site was on average less than that of a diesel operation.
The study is one of the first pre-feasibility level analyses of the technical and economic aspects of converting an Australian underground mine’s fleet from diesel vehicles to battery electric vehicles (BEVs). The study covered mine design optimization for electric operations, production and operating philosophy, fleet selection and power distribution and electrical infrastructure design. The partners also investigated electrification system and battery management, ESG and safety impact analysis and modelling of both CAPEX and OPEX costs.
Cosmos Nickel Project's planned underground diesel fleet includes heavy trucks and loaders, ancillary vehicles such as drills and charge rigs, and light vehicles, including four-wheel drive utility vehicles for transporting people and equipment.
Some BEVs would utilize battery swapping stations, typically switching out for a fresh battery two-three times per shift. Image Perenti 
It is anticipated that unproductive time would be minimized by strategically locating charging stations during points where vehicles are normally stationary, for example loading/unloading or during shift change. Image Perenti 
Study findings show that battery-electric trucks could replace diesel alternatives and match the haulage capacity required at the Cosmos Nickel Project. Image Perenti
“An all-electric mine is closer than ever, with the right equipment available and the mindset of the industry changing," said Raj Ratneser, Perenti Group Executive Sponsor for Electrification/Decarbonisation. "As BEV technology develops, and our understanding of how these vehicles can be best integrated into an operating mine improves, we expect electric mining solutions to only become more competitive against existing diesel powered options.”
“Mines can become even more energy efficient with vastly reduced levels of CO₂ emissions, while at the same time staying competitive and ensuring high productivity, in part due to the higher tramming speeds of electric loaders and trucks compared to their diesel equivalents," said Max Luedtke, Global Business Line Manager for Mining, ABB Process Industries. "We have been investing in electric mining transport through our eMine™ portfolio for several years now and have seen the technology go from strength to strength. We expect the outcome of this study to provide more momentum for electrification so our industry can continue to make real progress in lowering its emissions, while improving the health and safety of our people.”
Fully electric fleets are known to be more complex to manage than diesel fleets, but the study found that a BEV fleet at Cosmos could meet the required levels of productivity through a combination of strategically located battery swapping stations and charging points to minimise downtime. The study identified further areas for investigation, including more detailed modelling and simulation of BEV loading and haulage, power demand, BEV fleet optimisation, and more detailed consideration of the communication network to support an electric fleet.
“IGO is pleased to share this study with the wider industry as it demonstrates that the electrification of underground mining fleet is technically feasible, in the right circumstances," said Chris Carr, Acting Chief Operating Officer, IGO Limited. "The electrification of fleet at mining operations will be pivotal in the industry’s commitment to advancing towards net zero emissions. In addition, the removal of diesel from underground operations will eliminate diesel particulate matter and other diesel exhaust gases, resulting in improved working conditions and better health outcomes for employees.”
High level findings from the Study have been published in a White Paper. To access follow this Media Access link.
