Hitachi & ABB: Using EVs in Mining Decarbonisation

Heavy Duty Vehicles (HDVs) are responsible for more than a quarter of GHG emissions from road transport in the EU and for more than 6% of total EU GHG emissions, according to the European Commission.

Since 2021, ABB and Hitachi Construction Machinery (HCM) have partnered to develop the world's first fully electric haul truck.

The sustainable HDV was shipped to Zambia Kansanshi copper-gold mine in 2024 and has been under trial since.

Hitachi’s HDVs

The collaboration has produced the world’s first technological feasibility trial of an ultra-large full battery haul truck by an Original Equipment Manufacturer (OEM) as a customer’s mining site.

HCM’s ultimate goal is to transform trucks from diesel to battery electrification, using trials and ABB’s high-performance traction battery and high energy-efficient DC/DC converters.

When moving on level ground, the trucks run on internal batteries; however, when moving uphill, its onboard electric system draws energy from a trolley supply to power the motor directly – as well as charging a battery energy storage system.

When travelling downhill, the truck’s regenerative braking system charges the battery, reducing the charging load when it's connected to the trolley.

“This virtuous circle reduces the truck’s overall energy use and enables it to stay in continuous operation with no charging breaks and maintain high productivity,” says ABB.

"Hybrid and fully electric dump trucks are clearly the future, but the transition needs to begin now,” says Fabiana Cavalcante, Global Head of Mobile e-power at ABB.

“Big mining companies have their targets to achieve net zero by 2050 and this will not be possible if they don't electrify the mining truck fleets.”

Creating the all electric HDV

HCM announced the world’s first technological feasibility trial of an ultra-large full battery rigid frame dump truck by an OEM in June, 2024.

The feasibility trial began in June 2024 at First Quantum’s Kansanshi deep open-pit copper-gold mine – one of the company’s largest mines in Zambia.

“Mining companies around the world are working to reduce emissions,” says Eiji Fukunishi, Hitachi Construction Machinery’s Vice President and Executive Officer, President of Mining Business Unit.

“As Original Equipment Manufacturer, it is our vision to provide solutions that can reduce our customers’ environmental footprint. 

“The battery dump truck represents the future, not only for the Hitachi Construction Machinery Group but for the mining industry as a whole and we are pleased to establish this proving ground on an active mine site and work with First Quantum on advancing this zero emission solution.”

The trial aims to verify the basic performance of operations required of a battery powered dump truck such as: 

• Travelling
• Turning
• Stopping.

The truck was jointly developed with ABB Ltd (ABB), drawing on HCM’s experience with trolley dynamic charging, aiming to operate continuously by charging directly from overhead lines and through regenerative braking without stopping, enabled by ABB’s battery system. 

With environmental awareness rising across mining, interest in electrifying machinery to cut GHG emissions is growing; to meet demand for electric dump trucks, HCM began collaborating with ABB in June 2021 and signed a letter of intent with First Quantum on 1 March 2023 to establish a zero-emission partnership.

“Battery zero emissions development with little to no impact on payload, production and fleet size is achievable with Trolley Assist and First Quantum have mastered this technology by working with 2,600V systems of Hitachi Construction Machinery to provide stable platforms with multiple trucks on the overhead line at the same time,” says John Gregory, First Quantum’s Director Mining. 

“This system is operational, practical and economical feasible solution that will reduce emissions in mining for many years to come.”

 A test machine was completed and shipped to First Quantum on 20 January 2024, assembly was finished in Zambia and a technological feasibility trial begun following confirmation of basic operation. 

The HCM Group is aiming to accelerate efforts to bring the full-battery dump truck into practical use while co-creating with customers to help achieve net zero emissions from mining machinery.

Features of the dynamic charging battery truck

"By drawing electrical power from the dynamic charging system required during operation, it will limit the volume of batteries on the truck, providing a sustainable solution," says Hitachi.

The system also aims to reduce lifecycle costs along with the environmental impact through life cycle assessment by drawing electrical power from the overhead system while connected, simultaneously charging the battery in an appropriate manner to reduce the load and depth of discharge, maximising battery life

Limiting the battery volume also aims to lessen the weight of the battery solution on the vehicle, maximising the battery dump truck’s payload capacity.

The solution draws electrical power from the dynamic charging system during operation while simultaneously charging the battery, removing the need to stop the vehicle for recharging.