Electrifying mining vehicles offers a compelling answer to these challenges. Electric drivetrains deliver superior traction, lower operating and maintenance costs, and cleaner operations. Yet, full fleet electrification doesn’t happen overnight. Mines need significant preparation - power management, charging infrastructure (static or dynamic), and construction permits. Meanwhile, diesel trucks are still being manufactured and will remain in service for another 10–15 years, creating a real challenge for fleet legacy management.
Engineered for Profitability
Instead of waiting for a distant fleet renewal, latest technological developments make the upgrade and hybridization of existing diesel trucks not only technically feasible, but also financially very attractive.
Those diesel trucks, which could weigh more than 500t fully loaded, currently waste all the braking energy in braking resistor as heat. Instead, this valuable energy can be stored in batteries during downhill runs, and feed back to the motors when needed – the definition of a diesel hybrid upgrade.
The hybridization brings major fuel savings, boosts vehicle performance and reduces maintenance tasks for the diesel engine by lowering its load factor. Besides, it also helps to extend the asset life. Together, those benefits ensure a fast return on investment, typically ranging between 2 and 4 years.
Hybridization also provides valuable field experience with battery system to mine operators, easing the transition to full electrification later. It is a smart and cost-effective way to prepare for the transition.
The Case for Electrification
Whether through new builds or upgrades, ABB’s drivetrain solutions help operators to electrify and modernize, efficiently and sustainably.
Electric drivetrains deliver power directly to the wheels, eliminating mechanical inefficiencies and enabling faster operation, reduced cycle times, and greater reliability. By 2030, the total cost of ownership for a battery electric vehicle is expected to be 20% lower than a diesel truck, thanks to 20-30% lower maintenance fees and 40-60% lower fuel costs.
ABB brings the expertise needed to prepare mining operations for a successful electrification journey. This transition is inevitable and by partnering with ABB, mining operators make a future-proof investment.
ABB’s collaboration with Nuh Cement last year showcases this in action. The project transformed Nuh Cement’s haul truck into a fully electric, zero-emission vehicle – the first for a vehicle of that size and class. ABB’s contribution to the project included a BORDLINE® CC200, traction battery, an air-cooled traction motor, vehicle control electronics, a battery thermal management system, and a DC Fast charger. The result was a cleaner, quieter and more efficient machine that will save approximately 100,000 litres of fuel and avoid 245 tons of CO2 emissions annually.
Retrofitting and hybridization enable operators to act now, enhancing fleet performance and productivity, reducing emissions, and gaining valuable experience with electric systems, without requiring major infrastructure changes. For many, it’s the easiest and most efficient way to bridge the gap between today’s diesel reality and the fully electric future.
Moreover, these upgrades are backed by a strong business case: fuel savings and reduced maintenance costs deliver a rapid return on investment, making the transition both practical and profitable.
The environmental benefits of electrifying the mining industry are equally compelling. ABB estimates that if every truck worldwide were to be electrified, every single day we could remove 198,000 tons of CO2 from the air we breathe.
The Smart Choice
Mining is entering a decisive decade as priorities shift, and pressure rises. Electrification is not just a technological upgrade but a strategic advantage. By reducing the total cost of ownership, enhancing productivity, improving safety and slashing the environmental consequences, electrification offers an integrated solution.
Retrofit and hybridization ensure that no vehicle is left behind. It’s an efficient and sustainable way to accelerate change without compromising on performance or profitability.
With ABB’s expertise in both new and retrofit electric drivetrain solutions, we can send a clear signal to communities and investors that mining can lead the charge in sustainable industrial transformation. This is how we are helping the mining industry outrun leaner and cleaner.
