ABB: A Step-by-Step Guide to Building an All-Electric Mine

In a word-association game, “mining” is likely to trigger “drilling”, “digging”, “coal” and “extraction”. Not “clean”, “green” or “sustainable”.

That is unless you play the game with executives from automation machinery manufacturer ABB, which is among the companies embedding electrification in the industry.

Its latest whitepaper, Building the All-Electric Mine, is a roadmap for mining companies and their suppliers to change the industry’s reputation and reality.

According to ABB, the past few years have demonstrated that electrification significantly reduces emissions while enhancing operational output. From haul trucks and loading equipment to conveyors, the industry can now electrify a wide range of essential machinery.

ABB highlights that every site can take steps towards an “all-electric mine”, where small, smart shifts deliver significant performance gains. This transition is becoming increasingly critical, not least because the mining industry currently accounts for up to 7% of all greenhouse gases globally.

Impact of declining ore grades

As ore grades continue to decline, more energy is required to extract and process the same amount of metal. This reality, combined with the fact that new mining projects are often located in remote areas far from established power infrastructure, makes the integration of renewable energy sources essential.

ABB says this ensures reliable, cost-effective and low-emission operations across the mining value chain. Ultimately, this approach improves productivity, efficiency and safety.

However, ABB found 30% of mining leaders report being behind their 2030 decarbonisation targets. This figure reflects the pressure on operational managers, who must ensure that any technological change maintains or increases profitability while putting safety first.

ABB believes in starting small but thinking big by advancing technology and transforming mindsets through collaboration.

Securing materials for sustainable progress

The whitepaper says the mining industry will have to collaborate to supply the 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 in recent years, electrification has progressed significantly, ABB says, having been commissioned to conduct 26 studies across nine countries globally since 2021, providing blueprints for progress and building confidence.

Mining sector electrification data

• 7%: Proportion of global greenhouse gases from mining
• 30%: Leaders currently behind 2030 decarbonisation targets
• 53%: Leaders expecting transformation over the next five years
• 26: Studies conducted by ABB across nine countries since 2021
• 42%: Companies planning haulage decarbonisation investment by 2026
• 68%: Companies planning to electrify 25% of fleets by 2030
• 90%: Potential emission reduction using trolley assist infrastructure
• 2: Speed multiplier for electric trucks compared to diesel.

Reliability and speed of electric fleets

Sustainability arguments are always strengthened when they include increased profits, enhanced safety and other spin-offs.

ABB says Electric trucks tick all the boxes. They:

• Are twice as fast as diesel equivalents, significantly boosting productivity
• Have fewer moving parts, leading to reduced maintenance and downtimes
• Can be charged without human intervention
• Reduce harmful pollutants and noise levels, particularly in underground mines.

When the trucks and connected devices are autonomous, personnel no longer have to carry out dangerous tasks.

Managing power stability and energy volatility

Integrating electric vehicles can lead to more volatile energy load requirements, particularly when renewables power remote sites. ABB suggests that electrification is not just about replacing fuel; it is about smarter mining.

Power balancing solutions and robust planning of grid infrastructure can ensure a stable, reliable energy supply. By combining battery energy storage systems with mine production forecasting, operators can minimise load peaks and address volatility on the generation side.

Additionally, those relying on electricity are protected from volatile fossil fuel prices. Digital monitoring and automation tools also prevent failures before they happen.

This integrated approach reduces operational complexity, allowing teams to manage the final stage of the electrification journey without overloading the existing power grid or supply.

Principal strategic electrification concepts

ABB’s whitepaper includes seven simple steps that help executives to break down the journey to electrification:

• Start small, think big: focus on smart shifts that deliver major performance gains
• Proven technology: electrification is no longer futuristic but a proven reliability upgrade
• Mutual benefits: automation and electrification are beneficial to one another in mines
• Interoperability: charging infrastructure follows open standards to remain vendor-agnostic for multi-vendor fleets
• Talent attraction: modern digital technology and improved air quality are essential for attracting Gen Z talent
• Energy as an asset: Power is a critical resource directly affecting productivity, safety and operational uptime
• Collaborative Spirit: Advancing technology and transforming mindsets through collaboration allows teams to experience minimal disruption and carbon and financial savings for the long-term future of global mining.

Workforce health and talent acquisition strategies

Retraining operators accustomed to diesel fleets is a common concern for mining teams. However, ABB highlights that automation works with miners rather than against them, streamlining workflows.

The absence of diesel fumes means better air quality and healthier workers, while electric systems reduce fire and explosion risks. Reduced vibration and noise lead to less employee fatigue, resulting in fewer accidents.

Technology is also a significant draw for younger workers. With an ageing workforce, mines that do not adapt may struggle to attract new talent. More than two-thirds (68%) 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 the negative perceptions of the industry and empowering current employees.

Dynamic and stationary energy transfer technologies

For large haul trucks to be electrified, mines require a combination of stationary and dynamic energy transfer solutions.

ABB supports this shift through partnerships with Original Equipment Manufacturers, providing onboard equipment such as batteries and inverters. This allows mining teams to retrofit diesel trucks to improve safety and boost productivity.

Mapping mine constraints, such as loading areas and power availability, is essential for successful implementation, ABB says. 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 with limited idle time, while slow onboard systems suit stationary equipment like drill rigs.

These flexible solutions are built on open standards, ensuring they can be used by all vendors and are adaptable to specific mine designs, layouts and operational use cases.

Innovations in underground trolley system testing

ABB highlights trolley-assist systems as a dynamic charging solution, feeding power into diesel-electric trucks through overhead lines.

ABB collaborated with Epiroc to deploy the first fully battery-electric trolley truck system on an underground test track for Boliden. This system has since been extended to a 5km segment, bringing the industry closer to the all-electric mine of the future.

Energy is recovered through regenerative braking on downhill sections. New trolley systems are being designed for full re-locatability, featuring modular pre-cast foundations and lightweight suspension systems.

Automation and electrification are mutually beneficial, with control platforms integrating 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.