Mine Electrification

Technology Landscape in Decarbonisation & Electrification

As the global consciousness and regulatory pressures around climate change intensify, mining operations must strive to decrease their carbon emissions and embrace more sustainable practices. The Australian government has set ambitious greenhouse gas (GHG) reduction targets: by 2030, GHG must be 43% below 2005 levels. By 2050, they must be at net zero. This incentive is echoed by major mining companies. Most of Australia’s and the world’s mining companies have committed to similar targets.

For these targets to be met, a significant push towards the adoption of green technologies must occur. Modern electrified machinery and decarbonisation technologies both present promising pathways to this future. However, significant gaps still exist in their development, adoption, and implementation.

Firstly, there is a pressing need to integrate renewable energy sources into mining operations. Solar and wind energy have seen increasing exploration and use, but their intermittent nature and the intense energy requirements of mining operations present substantial hurdles. Effective and efficient energy storage solutions, such as advanced battery technologies or hydrogen storage, are crucial to overcoming these challenges.

Green hydrogen could provide a large-scale flexible energy storage solution. While it is gaining traction, significant research and development is needed to improve the efficiency and economic viability of green hydrogen production, storage, and utilisation.

Another key gap lies in the electrification of mining equipment and machinery. The potential of battery electric vehicles is already demonstrated through their increasing presence in everyday life, but adapting these technologies for large-scale, heavy-duty mining equipment presents significant challenges. Further research is needed to develop efficient, safe, robust, and high-capacity electric systems suitable for the intense demands of mining operations.

The journey towards decarbonising the mining industry is a complex, multifaceted endeavour that requires concerted efforts to innovate, improve existing technologies, and fundamentally rethink operations. The vision of a future where mining aligns with sustainable practices is attainable, but first, we must diligently address the gaps in decarbonisation technologies. By identifying and tackling these gaps, Mining3 seeks to direct its innovation and collaboration efforts towards crafting a more sustainable and resilient mining industry.

Mine Electrification Overview

In 2017, the mining industry accounted for 10% of Australia’s energy consumption (ARENA Report 2017, 2017), hence the pressure on mining companies to ensure that their energy is responsibly generated and used. Mines are currently heavily reliant on electricity from the power grid and on diesel-fuel powered machinery/vehicles.  A snapshot of the technology landscape driving changes in mine electrification is outlined in this section. Current issues that exist due to reliance on the grid power include:

• Greenhouse gas emissions;

• High consumption costs;

• Significant investment from the mine into power transmission lines and other mine site infrastructure; and

• Costly production losses when the grid becomes unreliable.

The mining industry has made attempts to replace diesel trucks and other large vehicles with counterparts that are powered with alternative energies; however this has resulted in building costly infrastructure such as trolley-assist haulage systems.  Much older large-scale electric mining machinery also exists which utilises high voltage trailing cables, which can be very hazardous to personnel.

In the big picture, these issues can be addressed by replacing reliance on a singular, fossil fuel power grid with local power grids throughout the mine powered by renewable energy sources (sun, wind, hydro, bio, and geothermal). A flexible grid network is also required to adapt to the ever-changing layout of the mine as mining advances. 

Already, mining companies are aiming to meet these targets. A commitment towards renewable and alternatively powered fleet technologies has been put forth by most major global mining companies, including those shown below, in their respective climate change and sustainability reports (Newcrest, 2023; Rio Tinto Climate Change, 2022; BHP Climate Transition Action Plan, 2021; Evolution Mining, 2023; Glencore Climate Report 2022, 2022; Antofagasta, 2023; Thiess, 2022; Armstrong McKay et al., 2022; Mercer & Edwards, 2021).

A move away from diesel is a huge driver, particularly for underground mines, as diesel engines radiate a lot of heat, emit noxious carcinogenic particulates into the atmosphere, and are a substantial source of carbon emissions in mining. Therefore, replacing them with low or zero-emission counterparts, such as battery electric motors, is also a necessity for the health and safety of personnel. Additionally, eliminating this problem will greatly reduce the exorbitant power requirements for underground ventilation and cooling, which currently combat the heating and air particulates produced by diesel engines.

Stepping into 2030 and beyond, the electric mine will have many different characteristics to current mines. Like any system, electric mines will have their negatives, however extensive research, such as that cited below, firmly shows that the economic and environmental benefits outweigh these. An overview of the electric mine of the future is provided in the table below. The items in red are the challenges, while green items are the benefits.

What the Electric Mine Looks Like: A Characteristic Approach
Business/ economic	Higher up-front costs for the new technologies (Anyadike, 2023) (How Electrification Is Changing Mining, 2021)  A better ESG standing, which may assist mine approval  Improved long-term cost/profit margins  Reduced GHG emissions & carbon tax costs (“The Electric Mine Working Group,” 2019)
Infrastructure	Smaller machinery powered from batteries or renewable energy  Microgrids of renewable energy power sources throughout the mine   Vehicles and machinery powered by batteries & clean energy fuel cells
Operational	Flexible micro grids accommodating continuous changes as the mine advances.  More reliable power grid.  Improved machine efficiency. (Mine Electrification: Towards an Electric and Renewables Mining Future, 2020)  Machine automation & condition monitoring. (“The Electric Mine Working Group,” 2019)  Improved power/energy management & energy usage analysis.  Reduced energy consumption per tonne hauled/mined. (How Electrification Is Changing Mining, 2021)  Response to the terrain and mining/drilling conditions.   Less reliance on, and hence more efficient, ventilation in underground mines. (Mine Electrification: Towards an Electric and Renewables Mining Future, 2020)
Safety	Diesel fuel particulates eliminated.  HV trailing cables & transmission lines eliminated.

Challenges and Opportunities in Decarbonisation & Electrification for the Mining Industry 

A transition to an electric mine involves challenges, gaps and opportunities. Mining3’s aim is to overcome challenges, develop solutions to close the gaps to an electric mine, and capitalise on the opportunities the electric mine presents. 

Overcome: Recognise the gaps between the present mining industry and the electric mine of the future, and safeguard against potential threats. 

• Challenges and costs of building renewable energy capacity 

• Intermitted nature of renewable energies 

• More complex power grid 

• Existing limitations with BEVs (life, range, specific energy) 

• Need for frequent charging and charging time 

• Lithium battery hazards (explosions) 

• Cybersecurity attacks 

  
  

Develop: Mining3’s capability can bridge the gap to an electric mine using technologies such as the following: 

• Wireless power transfer charging & mobile charging stations 

• Retrofitting: As many as 1 million diesel mining vehicles will need to be retrofitted to electric by 2030 (Critical Minerals – Topics, n.d.).  

• Modelling energy consumption of vehicles and micro grids 

• Modelling of complex and power-hungry machinery  

• Power network analysis for electric rope shovels 

Capitalise: recognising the hidden safety and productivity potential an electric mine can unlock. 

• Improved automation & collision avoidance. 

• Micro-grid monitoring with fibre optic sensing technologies 

• The opportunity to integrate new and adaptive Internet of Things technologies such as autonomous vehicles and machinery, communications networks and data analysis 

• Regenerative power recovery & storage in electric vehicles 

• Improving logistical downtime through automation and monitoring 

• Handling & modelling high dynamic load changes (such as using AI) 

Mining3’s research and development capability and mine modelling expertise can help bring the electric mine closer to realisation. In the last five years, Mining3 has completed 13 projects with a value of over three and a half million dollars directly related to decarbonisation through electrification. The research has ranged from the development of autonomous battery-electric hauler concepts, hydrogen fuel cell trial in high-altitude mines, simulation, value modelling to compare various alternative haulage solutions, and wireless power for mobile equipment. We have the resources to help position the industry on the front foot in terms of ESG and we want to accelerate the industry towards being more safe, environmentally sustainable, and more productive.