Electrified vehicles, battery storage, and autonomous technology are key focuses in the mining industry as companies work towards net-zero targets and more sustainable operations. A significant challenge remains ensuring fast charging and regenerative energy systems to minimize or eliminate vehicle downtime. Hybrid solutions continue to support the shift to all-electric powertrains, while OEMs (Original Equipment Manufacturers) persist in refining hydraulic machinery. Ahead of MinExpo International 2024, here are some innovations released by OEMs since the 2021 event, as well as their future goals.

Battery Electric and Autonomous Mining Solutions Achieve Success

In 2021, Caterpillar introduced an Early Learning program to collaborate with customers on developing and validating its battery-electric prototypes. By 2022, these customers gathered for a live demonstration of Caterpillar's first battery-electric 793 mining truck. The prototype was built at Caterpillar’s Tucson Proving Ground in Green Valley, Arizona, which is known as the "mine site of the future" and aims to showcase sustainable solutions using various renewable energy sources.

During the demonstration, the 793 prototype was sent on a 4.3-mile (7-km) course, where more than 1,100 data channels were monitored, capturing 110,000 data points per second. The truck was fully loaded to its rated capacity and reached a top speed of 37.3 mph (60 km/h). It climbed a 10% grade for 0.62 miles (1 km) at a speed of 7.5 mph (12 km/h). On a 10% downhill grade, the truck regenerated energy that would typically be lost as heat, storing it back in the battery. The truck maintained enough energy to complete additional cycles after finishing the entire run.

Since then, Caterpillar has expanded its portfolio of battery-electric and semi-autonomous technology for underground mining applications. Late last year, the company successfully demonstrated its first battery-electric underground mining truck for gold miner Newmont and other industry leaders at a proving ground in Tasmania, Australia. The collaboration aims to realize Newmont’s vision of a fully connected, automated, zero-carbon-emitting, end-to-end mining system. When paired with the R1700 XE battery-electric loader, this new truck will complete Caterpillar's first fully electric underground load and haul solution.

Caterpillar also showcased its expanding autonomy and automation capabilities, addressing safety challenges such as collision risks in dark, confined spaces. Autonomous trucks can enhance mine site safety by removing operators from hazardous or remote areas. Moreover, these technologies can boost productivity by improving visibility for mine site coordinators, enabling more consistent operations across both staffed and autonomous machines.

At the World Mining Congress 2023 in Brisbane, mining services provider Thiess partnered with Caterpillar and Cat dealer Hastings Deering to demonstrate Thiess' semi-autonomous dozing operation using a remote operating station located more than 528 miles (850 km) away from the site. Thiess controllers remotely operated multiple Cat D11 dozers at the Lake Vermont mine in Central Queensland, live from Caterpillar’s event stand. This marked the first time multiple dozers had been controlled off-site using Cat MineStar Command for dozing’s semi-autonomous tractor systems (SATS) since the product became commercially available. With the autonomy layer activated, operators could manage multiple dozers simultaneously without being physically present at the site.

“We’ve seen improved safety, productivity, and efficiency benefits and have upskilled more than 100 employees on autonomous mining systems,” said Trent Smith, group manager of Thiess Autonomous Services, in a press release.

In 2023, Caterpillar also completed an in-house validation of Rajant BreadCrumbs LX5 CA radios, enabling field trials with Rajant’s wireless products and Cat MineStar Command for hauling.

Rajant offers Kinetic Mesh networking systems, which use fully autonomous nodes to maintain high performance in constantly changing environments. Through its patented InstaMesh routing technology, Rajant networks provide dynamic connectivity by routing traffic through the optimal path, adapting to shifts in network topology.

The wireless nodes from Rajant are equipped with multiple radios operating on various frequencies, allowing traffic to be routed through mobile nodes. This improves connectivity and throughput in dynamic settings, creating more radio paths for seamless communication. The next phase involves validating the solution with Cat MineStar Command for hauling at a mine site to assess performance and scalability.

New hydraulic machines are now available in hybrid versions.

Earlier this year, Komatsu unveiled its new WX11 load, haul, and dump (LHD) machine designed for underground hard rock mining. The machine boasts a payload capacity of 24,250 lb (11,000 kg), marking an 8 to 10% increase compared to similar LHDs. Its diesel engine delivers 280 hp at 2,000 rpm (209 kW at 2,000 rpm) and meets various certifications, including Canmet, MSHA, EPA Tier 3/EU Stage IIIA, and EPA Tier 4F/EU Stage V.

The WX11 is equipped with integrated data management, ergonomic features for operators, and intuitive controls. It also complies with EU Stage V emission standards. Notable additional features include heavy-duty hard rock axles with spring-applied hydraulically released (SAHR) brakes and reinforced structures to support the increased payload capacity.

Komatsu also offers two hybrid LHDs, the WX18H and WX22H, equipped with switched reluctance (SR) hybrid drive systems. These systems capture and store energy through a kinetic energy storage system (KESS). Komatsu claims that this hybrid technology can reduce fuel consumption by 30% compared to traditional diesel LHDs while boosting power by 550 hp, potentially increasing tons moved by 20%. This not only lowers operating costs but also reduces emissions.

In addition to its LHDs, Komatsu introduced the second generation of its Z2 product line for small-class development drill and bolting equipment. Initially launched in 2020, the small-class ZJ21 jumbo drill and ZB21 bolter featured a common platform. The new Z2 bolters and jumbos focus on maximizing operator comfort and visibility while enabling ground-level maintenance. The updated ZB21 bolter includes a fully enclosed ROPS/FOPS-certified operator cabin, integrated patented screen handling, and Montabert-manufactured drifters.

The ZB21 bolter also offers an optional Komatsu pumpable resin system, using J-LoK P by Jennmar, which allows operators to pump resin into drilled holes before bolt installation. This system enables the use of more cost-effective bolts and helps reduce overall installation costs.

The second-generation ZJ21 jumbo drill is a single-boom development drill with a fully enclosed ROPS/FOPS-certified operator cabin, innovative drilling feeds, advanced pilot hydraulics, and drifters manufactured by Montabert.

Both product lines now include battery-electric versions with onboard, smart, opportunistic charging. The ZB21 and ZJ21 are the company’s smallest size-class drills and bolters with a battery-electric option and have a modular battery driveline with 83 kW-hr of onboard energy. Komatsu aims to support underground operations with these new mining innovations as the industry shifts toward electrification.

Energy storage and electric-diesel options are underway

As the mining industry moves toward electrified operations, energy storage quickly becomes a top priority. Sandvik has initiated a pilot project to deploy a second-life battery energy storage system (BESS) for Glencore, a Switzerland-based natural resource and commodity company. The BESS is expected to support mine services, such as lighting and light electric vehicle (EV) charging at Glencore’s operations. Sandvik will study additional use cases during the pilot, including power shifting, peak shaving, and arbitrage.

Sandvik’s technology partner in the project is Eco Stor, a second-life energy storage system provider based in Olso, Norway. Eco Stor will develop the solution with modules recovered from Sandvik battery-electric vehicles (BEVs) that have reached their optimal use in mobile mining applications.

“Modules can be easily replaced when they reach the end of their second life. Ensuring the batteries that power our mining equipment are used to their full potential before being recycled improves circularity and substantially reduces our carbon footprint,” said Ville Laine, VP of Batteries and Chargers at Sandvik Mining and Rock Solutions, in a press release.

The Battery Energy Storage System (BESS) will be housed in an industrial 20-foot container that holds 128 Sandvik battery modules, with a nominal energy capacity of approximately 1 MW-hr. The container will feature Sandvik systems for battery and energy management, as well as fire detection and prevention.

"Due to the early adoption of our battery systems across global mining operations, thousands of modules will soon reach the end of their first life," said Ville Laine, VP of Batteries and Chargers at Sandvik Mining and Rock Solutions. "These modules still retain up to 70% of their original energy storage capacity, even after their optimal use in mining trucks and loaders. Repurposing this remaining capacity for stationary energy storage is a win-win—benefiting both the environment and the economy. We can extend the useful life of these batteries and optimize their full lifecycle."

Sandvik plans to deploy the prototype BESS at a Glencore asset in 2025 and aims to introduce a commercial solution by 2026. Once commercialized, the company intends to assemble each BESS as close to the customer’s mine as possible to reduce shipping costs and further enhance sustainability.

However, Byrnecut Australia, a contract miner, predicts that the transition to battery-electric equipment will be gradual, with electric, diesel, and hybrid machines working together. Sandvik Mining and Rock Solutions shares this view, stating that the future of mining will likely involve a combination of technologies.

As a result, Byrnecut is working with Sandvik to develop new diesel-electric mining machines designed to improve sustainability, efficiency, and underground productivity. Diesel-electric machines use a diesel engine to power a generator, which supplies electricity to motors responsible for movement and equipment operation. Unlike traditional diesel-powered machines, diesel-electric models have fewer moving parts, making them easier to maintain and more cost-effective while maintaining high availability.

In line with this, Sandvik announced its plan to develop a diesel-electric range of underground loaders and trucks to complement its battery-electric offerings. This move follows the demonstration of its Toro diesel-electric truck at a technology workshop in Turku, Finland, in 2022.

For those ready to transition to fully electric equipment, Sandvik introduced the DR416iE, the next-generation electric rotary blasthole drill. The DR416iE is suitable for iron ore and copper applications, with a drilling range from 10.6 to 16 inches (270 to 406 mm). Powered by a 1,400-hp (1,044-kW) electric power unit, the drill is built to handle high-altitude demands. Its electric system includes a soft starter to reduce strain on the mine’s power grid, preventing disruptions to other equipment. The drill also features a multi-voltage and multi-frequency motor for flexibility, with an optional 1,378-ft (420-m) cable reel for easy connection to the mine substation.

For hard rock formations, the DR416iE is equipped with a heavy-duty, hydraulic motor-driven chain feed system. This system enhances pulldown force and increases weight on the bit, resulting in significantly faster penetration rates.

Sandvik’s goal is to ensure a smooth transition from diesel to electric equipment. To achieve this, the DR416iE utilizes the same modular platform as Sandvik's diesel-powered rotary rigs and integrates the DRi control system, which is featured across all Sandvik i-series surface drills.

Digital Mining Innovations Enhance Safety and Efficiency

Last year, Hitachi Construction Machinery established a Technological Center of Excellence (TCoE) to support mining sites utilizing its dump truck Autonomous Haulage System (AHS). The company’s goal is to offer AHS solutions worldwide, improving safety and overall operational efficiency. Earlier this year, Hitachi announced that it would begin full-scale remote monitoring of AHS from its center in Brisbane, Australia.

At the TCoE, a team of about 20 experts monitors real-time data from mining sites, similar to the information received by Hitachi's AHS customers in their control rooms. Specialists in mining machinery, operations, and software use advanced digital technologies to collect, analyze, and interpret data from various mining sites. The insights gathered are then used to find solutions to customer-specific issues, optimizing mine operations. Looking ahead, Hitachi plans to evolve the TCoE into a central hub for coordinating its mining solutions business. The center will leverage digital technologies and accumulated expertise to create new value and provide ongoing support from the customer’s perspective.

Hitachi began its research into Autonomous Haulage Systems (AHS) in 2009 and has been validating the technology at an Australian test site since 2013. This research has focused on achieving sequential mining operations for loading, hauling, and dumping using autonomous dump trucks. In July 2018, Hitachi partnered with Whitehaven Coal, and after approximately six years, the company confirmed that its AHS had reached a practical level of performance. Moving forward, Hitachi plans to roll out AHS to mining customers worldwide, aiming to enhance safety and productivity across the industry.

This year, Hitachi also unveiled its new Operator Assist System, designed to support the operational performance of ultra-large hydraulic excavators used in digging and loading. Operators of such heavy machinery are tasked with efficiently digging and loading materials onto dump trucks while avoiding contact with surrounding equipment. Through the introduction of the Operator Assist System, Hitachi seeks to reduce operator strain, boost safety on mine sites, improve productivity, and lower fuel consumption.

Hitachi has planned a verification test at one of Rio Tinto’s iron ore mines in the Pilbara region of Western Australia to showcase the practical application of its new system and improve its accuracy. The test will involve sensors, monitors, and other equipment attached to the EX3600-7 ultra-large hydraulic excavator, which will assess the digging and loading performance while also testing the usability of the monitor display. Hitachi expects to roll out the Operator Assist System in stages starting in 2025.

Since late last year, Rio Tinto has been assisting in the durability testing of a new boom and arm design for Hitachi’s ultra-large hydraulic excavators. The new design will be introduced to the EX5600-7 backhoe excavator in March 2025 and will gradually be applied to other compatible models. Hitachi's goal is to increase the service life of its equipment by 1.5 times compared to previous models, which will help reduce the emissions generated when an excavator is eventually scrapped.

This year, Hitachi also launched a feasibility trial for an ultra-large full battery rigid frame dump truck at First Quantum’s deep open-pit copper-gold mine in Zambia. The trial aims to assess the truck’s basic performance, including its ability to travel, turn, and stop under actual operating loads, as well as verify battery charging and discharging cycles. Hitachi developed this full-battery dump truck in partnership with ABB, and it operates by drawing electrical power from a dynamic charging system during operation, while also charging the battery. This approach reduces the battery volume, limiting its weight as a percentage of the vehicle's overall weight, and helps maximize the load capacity.