In an attempt to modernize the mining industry and reduce harmful emissions, Hitachi has introduced the world’s first ultra-large full battery dump truck at an open-pit copper/gold mine in Zambia. The innovative prototype is currently undergoing extensive validation testing to ensure its optimal performance under operational loads and support infrastructure.
Despite the traditional perception of mining as a polluting industry, several initiatives have been introduced to improve environmental standards, particularly in the area of heavy machinery. Established companies such as GM, Fortescue, Caterpillar, and Anglo American have previously endeavored to lower emissions during mining operations.
Initiated by Hitachi Construction Machinery in 2021, the project has collaborated with technology giant ABB to explore opportunities for mine operators to achieve net-zero emissions from mining machines. This partnership resulted in the development of a battery electric dump truck, which commenced in June of the same year.
By 2023, First Quantum Minerals joined the partnership by agreeing to conduct feasibility trials for the truck at the Kansanshi copper/gold mine in Zambia. This move was particularly significant as the mine was already operating a number of Hitachi trolley trucks, making it an ideal testing ground for the new prototype.
The diesel-electric vehicles currently in operation at the site utilize an internal combustion engine for power, similar to regular trucks, but can also utilize overhead cables for electric-only operation. The introduction of a fully battery electric rigid-frame version would entirely eliminate diesel emissions, a critical development considering that Zambia meets 92% of its energy needs through renewable sources.
Initial testing of the prototype was successfully completed in January of this year, marking a significant milestone for the collaboration. The prototype, which is a modified version of the Hitachi EH4000 AC-3 model, stands at 47 ft in length, is powered by a 2,500-hp Cummins engine, and boasts a nominal payload of 243.6 tons.
The fully functional prototype has now been deployed to the Kansanshi mine in Zambia to undergo a technology feasibility trial. The partnership expects the truck to be capable of continuous operation due to the existing network of overhead charging lines combined with the prototype’s regenerative braking system.
Through the innovative dynamic charging setup, the size of the onboard battery pack is significantly reduced as the need for the truck to stop and recharge is eliminated. This is expected to lead to reduced production costs while maximizing payload capacity, ultimately presenting a practical and economically feasible solution for reducing emissions in mining operations for years to come.
John Gregory of First Quantum emphasized the advantages of the Trolley Assist system, stating that it provides a stable platform for multiple trucks on the overhead line simultaneously, resulting in little to no impact on payload, production, and fleet size. He expressed confidence in the system’s operational, practical, and economic feasibility, affirming its ability to significantly reduce emissions in the mining industry.
The provided video by Hitachi Construction Machinery offers insight into the innovative thinking behind the project and provides a glimpse of the static charging option currently under consideration.
Source: Hitachi Construction Machinery