Across the mining sector, businesses are looking to decarbonise. Hybridisation represents a powerful way to reduce costs, increase productivity and cut back on the emissions from diesel haul truck fleets.
The mining sector is under growing pressure to decarbonise operations while maintaining productivity and cost competitiveness in an increasingly uncertain world.
One source attracting industry attention is diesel emissions – and for good reason. Diesel combustion amounts to approximately 17 per cent of Australia’s total carbon emissions, and according to the Institute for Energy Economics and Financial Analysis, mining in Australia alone consumes approximately 9.6 billion litres of diesel annually, with mobile equipment producing around 22 million tonnes of carbon dioxide emissions in 2023.
Although the mining industry is embracing electrification as a cost-effective means of reducing emissions, that falls short as an immediate substitute for diesel. Fully electric haul trucks are still an emerging technology and require significant infrastructure investment, making large-scale deployment challenging for many operations in the near term.
But that doesn’t mean the cost savings from carbon reductions are out of reach in the short term. As Reza Taheri, Traction Sales Manager for Mobile e-Power at ABB Australia, points out, the mining industry can avoid the risks of soaring costs, sudden disruptions, and major unplanned investments with alternatives that are proven, cost-effective and available right now.
The hybrid approach
“We see hybridisation as a practical pathway for reducing emissions in mining operations today while also preparing fleets for future electrification,” Taheri said.
“This is a rapid and effective modernisation step that delivers a rapid return on investment with minimal disruption to operations.”
ABB’s hybrid solution consists of a high-power traction converter and battery energy storage system that is delivered as a hybrid power package integrated into existing diesel-electric haul trucks, enabling energy to be captured, stored and reused during the haul cycle.
This means existing fleets can reduce fuel consumption by up to 30 per cent, lower emissions and bring down maintenance costs over a vehicle’s life cycle, as well as increase productivity and improve availability by reducing downtime.
Adding to the fuel savings is the regenerative braking offered by the integration of a battery into the system.
“In a typical mining operation, a significant amount of energy is lost during braking and downhill travel,” said Pradip Savaliya, Product Manager for Traction at ABB Australia.
“In conventional diesel-electric haul trucks, traction motors operate in dynamic braking mode, converting mechanical energy into heat that is dissipated through braking resistors. With a hybrid system, this energy can instead be captured and stored in the battery. That stored energy can then be reused during acceleration or when the truck climbs a loaded ramp.”
By supporting the diesel engine during high-power demand, the hybrid system allows the engine to operate closer to its optimal efficiency range. Depending on operational priorities, the recovered energy can be used to reduce fuel consumption, improve productivity through faster cycle times or lower peak engine loads to reduce mechanical stress and maintenance requirements.
ABB’s retrofit package is designed specifically for diesel-electric haul trucks, replacing the existing traction converter with a form-fit ABB traction converter integrated with battery energy storage.
“Mining operators can benefit from traction technologies that have already been proven in other heavy-duty transport applications,” Taheri said.
“The technology builds on ABB’s extensive experience in traction electrification and hybrid retrofit projects in the rail sector, where similar systems have been used to modernise diesel fleets.”
Local service
For large mining fleets, access to reliable local support and life cycle service is critical to ensuring uptime and reducing operational risk.
“You cannot rely on complex supply chains or offshore service models when equipment availability directly impacts production,” Taheri said.
“ABB, however, has full-service capabilities right here in Australia. Our Traction Centre of Excellence is a battery service centre based in Maryborough, Queensland, that offers complete, life-cycle support.”
ABB’s 5000-square metre facility now manufactures highly efficient traction systems for large scale rail projects, serving as a strategic hub that supports a broader range of mobile electrification applications, including mining.
The facility offers advanced manufacturing capabilities, life cycle support and service.
While hybridisation provides an immediate and cost-effective pathway for reducing fuel consumption and emissions for mining operators, the technology and supporting infrastructure required for full electrification is growing more robust by the day. As such, ABB’s hybrid solution also establishes a future-ready platform for full electrification.
“The return on investment for hybridisation is two to four years, and the truck can be seamlessly converted to full battery-electric operation by replacing the diesel engine with more batteries,” Taheri said.
“If you eventually replace the entire diesel engine with a battery system, you won’t need to change the converter or the setup. Rather than waiting for full electrification, this is an opportunity to take a practical step today, reducing fuel, emissions and cost while improving productivity and building a clear pathway to fully electric operations.”
That means companies don’t need to start from scratch to reduce carbon emissions and fuel dependency, increase efficiency, and extend equipment life.
“We’re happy to work with our customers to put a precise return-on-investment together, since every mine has different operational conditions,” Savaliya said.
“This is the perfect time for the mining industry to take advantage of these gains, which have already been proven elsewhere, and to make progress on their sustainability goals.”
Learn more about how ABB’s hybridisation solution for heavy haul mining trucks can modernise your fleet.
