Diesel Innovations Drive Lower-Emission Mining Forward
The mining industry is increasingly prioritising reductions in greenhouse gas (GHG) emissions; around three-quarters of operators identify emission reductions as an integral component of their strategy and many have set specific carbon intensity goals. However, the pace of change is tempered by economic and operational realities.
The power mix in mining operations is currently split between grid electricity and diesel. On average, grid power supplies about half of a mine’s energy needs for tasks such as crushers, mills and ventilation. Meanwhile, diesel powers haul trucks, loaders and other ancillary equipment, underscoring its large role in sustaining mining operations.
Although battery-electric vehicle (BEV) technology is gaining attention, its current adoption in mining is minimal. Underground operations have begun integrating BEVs, but for large surface mining trucks, the engineering and infrastructure challenges remain significant.
Diesel-powered equipment is therefore expected to dominate operations until 2040 due to the cost of heavy equipment, its long lifecycle and the physical demands of mining. As a result, operators are turning to more efficient diesel technologies and bio-based drop-in fuels as interim solutions while they prepare for a more electrified future.
The diesel efficiency toolkit
As full electrification remains a longer-term goal, many mining operators are focusing on improving diesel efficiency. This involves optimising operations, deploying advanced fuels and adopting new technologies to reduce emissions, fuel consumption and costs – all while increasing productivity.
The chemistry of diesel fuels plays a key role. Performance diesel with advanced detergent technologies can preserve combustion efficiency by maintaining engine cleanliness. Pairing these with synthetic lubricants for engines, transmissions and drivetrains enhances operational efficiency. Given that a single ultra-class haul truck can annually consume close to a million litres of diesel, even incremental improvements at the engine or drivetrain level can deliver fleet-wide benefits.
Data and analytics are another critical component of effective fuel management. Mining operations often run haul trucks for up to 18 hours a day, making inefficiencies such as idling, queuing or poor routing costly in terms of both fuel and emissions. Comprehensive fleet management systems and on-board telemetry enable operators to identify inefficiencies and streamline operations. For example, real-time data can help pinpoint idle hotspots and reduce unproductive engine hours, directly lowering fuel consumption.
Autonomous operations
Automation has emerged as a powerful tool for improving fleet efficiency. Autonomous haul trucks increased from 1% to 4% of mining fleets between 2021 and mid-2025, and their adoption continues to grow. Automated trucks offer consistent throttle control, smoother braking and more disciplined operation, which reduces fuel burn and minimises component wear. These benefits compound over time, translating to better tire life, lower maintenance and greater fuel efficiency.
Meanwhile, targeted equipment upgrades are providing near-term solutions for reducing emissions. Deploying newer-generation diesel engines and diesel-electric hybrids offers immediate efficiency gains. Features like improved turbocharging and advanced engine controls help these systems achieve lower fuel consumption, while diesel-electric drives provide some of the efficiency advantages of full electrification without the accompanying infrastructure challenges.
Another promising solution is renewable diesel, also known as hydrotreated vegetable oil (HVO). Renewable diesel is a drop-in replacement for conventional diesel, requiring little or no engine modifications. Its lifecycle GHG emissions are lower compared with fossil fuels and several OEMs already support its use. With global production capacity for renewable diesel projected to triple by 2030, it is becoming an increasingly viable option for mining operations. Early trials, such as those conducted at the Kearl Oil Sands site in Canada, have shown that renewable diesel can deliver comparable power and performance, even in harsh environments.
Integrated approaches to efficiency and emissions reduction
Mines rely on close coordination across maintenance, operations and procurement teams, and integrated solutions can help streamline these processes. ExxonMobil, for instance, offers a comprehensive program that combines performance diesel fuels, synthetic lubricants and renewable fuel options. Its approach begins with establishing clear baselines for fleet performance, followed by tailored recommendations for lubrication plans, fuel trials and data-driven insights to improve day-to-day operations. This holistic effort is supported by real-time monitoring and clear key performance indicators (KPIs) to help ensure operators can measure progress and effectively scale their efforts effectively.
The path forward
Diesel efficiency remains a priority as mining transitions toward electrification. By integrating advanced fuels, new technologies and precision data management, operators can improve productivity while reducing emissions and costs. Renewable diesel offers a promising interim solution, enabling lifecycle GHG emission reductions vs conventional diesel without requiring major capital investments.
For those seeking to explore lower-emission solutions in mining, ExxonMobil offers expertise and resources to help operators achieve this transformation. To learn more, consult Mining Forward, ExxonMobil’s white paper on the potential for lower-emission mining operations.
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