ABB's Seven-Step Guide to Mining Electrification

The global mining sector faces mounting pressure to decarbonise, yet its pathway to net-zero remains far more complex than many other industries. Mining accounts for approximately 7% of worldwide greenhouse gas emissions while simultaneously supplying critical raw materials for renewable energy infrastructure, creating an urgent need to clean up operations.

Declining ore grades mean significantly more energy is needed to extract the same volume of metal, while new projects are pushed into remote locations with limited grid infrastructure.

Against this backdrop, automation manufacturer ABB has released a white paper titled Building the All-Electric Mine, outlining a practical framework for mining companies to rethink energy sourcing, usage and management.

According to ABB's research, 30% of mining leaders currently report falling behind their 2030 decarbonisation targets. However, its analysis suggests that electrification could substantially cut emissions while simultaneously lifting operational output, with technology now existing to replace diesel-powered machinery across haulage, loading and conveying operations.

Electric fleets boost productivity

The most compelling arguments for electrification emerge where sustainability and commercial logic align.

Electric haul trucks operate at twice the speed of diesel counterparts, significantly boosting throughput while featuring fewer moving parts that cut maintenance costs and reduce downtime. Many can be charged autonomously, removing the need for human intervention.

Underground mining operations stand to gain particularly substantial benefits. The elimination of diesel exhaust improves air quality considerably, with direct benefits for worker health and safety. Reduced noise and vibration lower fatigue levels, while electric systems remove fire and explosion risks associated with combustion engines.

Since 2021, ABB has completed 26 electrification studies across nine countries, according to the white paper. The research found that 42% of companies are planning haulage decarbonisation investment by 2026, while 68% are planning to electrify 25% of their fleets by 2030.

The transition to electric fleets represents more than an environmental initiative. The operational advantages create a business case that stands independently of sustainability mandates, positioning early adopters to gain competitive advantages in efficiency and cost management.

Managing energy as operational asset

Introducing large-scale electric vehicle fleets fundamentally alters the energy load profile of a site.

Charging cycles can create volatile demand peaks, particularly where renewables are the primary generation source, requiring mining operators to treat power as a strategic operational resource.

ABB's approach advocates for robust grid infrastructure planning from the outset, supported by digital monitoring and automation tools. Battery storage systems, combined with real-time production forecasting, allow operators to flatten demand curves and reduce supply disruption risk. Mines that depend on electricity gain insulation from diesel price swings while gaining greater visibility into energy costs through digital monitoring platforms.

The white paper distils the journey into seven guiding principles:

• Start small and think big
• Rely on proven technology
• Leverage mutual benefits as automation and electrification reinforce each other
• Prioritise interoperability by building charging infrastructure on open standards
• Use technology to attract talent
• Treat energy as a core operational asset
• Collaborate throughout the supply chain

This structured approach allows mining operations to phase implementation according to capital availability and operational priorities, reducing risk while building towards comprehensive electrification.

Trolley assist delivers emissions reduction

Among the most significant innovations highlighted in ABB's research is trolley-assist technology, which feeds power into diesel-electric trucks via overhead lines.

ABB collaborated with Epiroc to install the world's first fully battery-electric trolley truck system on an underground test track operated by Boliden, subsequently extended to a 5 km segment.

The technology offers considerable energy efficiency gains, with regenerative braking on downhill sections recovering energy that would otherwise be lost as heat. New trolley systems are designed to be easily relocated, with modular pre-cast foundations and lightweight suspension. ABB says this approach could deliver up to a 90% reduction in haulage emissions.

ABB works with original equipment manufacturers to supply onboard components – batteries and inverters – enabling diesel trucks to be retrofitted rather than replaced outright, reducing capital requirements and disruption. Stationary charging systems are suited to periods when trucks are stationary, while fast offboard systems work well for vehicles in continuous use.

The workforce implications are also significant. More than two-thirds of survey respondents (68%) identified technology adoption as a driver of diversity and a means of attracting younger workers, according to ABB's research.

ABB's position is that automation assists rather than displaces the workforce, streamlining tasks and removing humans from dangerous environments. Cleaner, quieter and more digitally-sophisticated operations could change the proposition for prospective employees considerably.