The global mining industry has long relied on high-powered, heavy equipment to extract raw materials from underground and open-pit mines.
However, lithium-ion battery-powered vehicles (BEVs) are having a significant impact across the mining industry.
These devices are reshaping how mines operate, with profound implications for sustainability, productivity, and overall costs.
This article explores the current status of zero-emission, all-electric vehicles in mining, focusing on the latest research findings and examining the challenges and opportunities of adopting all-electric equipment.
The global mining industry is accelerating its shift to battery-powered equipment
Mining companies are gradually replacing diesel equipment with battery-electric vehicles (BEV) in both surface and underground operations. Emission reduction targets, regulatory compliance, and cost considerations are driving this shift.
A recent market analysis from Global Mining Review shows that electrification has become a core component of the mining industry’s decarbonization strategy, with 91% of surveyed companies considering it critical to their sustainability plans.
Industry forecasts indicate that the market for electric mining trucks, loaders, and light vehicles will continue to grow steadily, with a projected compound annual growth rate (CAGR) of 32% through 2044.
Environmental benefits of BEV electric equipment
Unlike diesel engines, BEVs can achieve zero greenhouse gas and exhaust emissions on-site. Recent industry research indicates that electric mining equipment can reduce operational emissions by up to 50% compared to diesel equipment. Lower particulate matter emissions significantly improve mine air quality, protect miners’ health, and reduce ventilation energy consumption.
BEV Economics and Cost-Effectiveness
Electric mining equipment offers significant cost benefits throughout its lifecycle.
Electric motors have fewer components, significantly reducing maintenance and downtime. Electric energy costs are also significantly lower than diesel, whose prices fluctuate drastically.
While the initial investment for BEVs is typically higher than for diesel equipment, the long-term operating cost advantage will gradually offset the price difference. Research indicates that future declines in battery prices and advances in charging technology will further enhance their economic viability.
The 2024 Electric Vehicles in Mining Report highlights that advances in battery capacity, chemistry, and charging methods are continuing to extend equipment operating time and reduce the frequency of battery replacements.
Furthermore, BEVs excel at high altitudes, while diesel equipment often suffers from performance degradation due to the thin air. As battery energy density increases, the range and power of electric equipment will continue to improve, making them reliable for a wider range of tasks.
Safety Advantages of Electric Mining Equipment
Electric motors operate with lower noise and heat generation, effectively reducing noise exposure and heat stress risks to workers, creating a safer and more comfortable working environment.
BEVs completely eliminate diesel exhaust and reduce respirable dust, significantly reducing respiratory health risks for miners. Improved occupational health and safety not only helps companies attract talent but also reduces workers’ compensation and medical expenses.
However, safety risks still exist in battery charging, replacement, and maintenance.
Researchers emphasize the need for strict battery operation, charging, and maintenance protocols to prevent electrical accidents and ensure safe operation under harsh conditions.
The study of mining workers provides important insights into risk perception and the effectiveness of new safety measures in the application of battery electric vehicles (BEV).
Workers urgently need safety training
Based on multiple studies, mine workers believe that the use of battery-powered vehicles in underground mining, while offering numerous benefits, also presents safety challenges.
Overall, workers highly appreciate the advantages of BEVs in reducing noise and eliminating diesel particulate matter emissions, believing that this results in a quieter and cleaner underground working environment.
However, they remain significantly concerned about the fire risk posed by high-voltage batteries due to collisions or improper operation, as well as concerns about battery life and charging.
Compared to traditional diesel equipment, miners noted knowledge gaps regarding BEV-specific emergency response, battery identification, and fire extinguishing methods. They emphasized the need for specialized safety training, clear operating procedures, and enhanced communication targeting emerging risks.
Interviews, surveys, and organizational reviews revealed that miners’ risk perceptions are influenced by their personal experience, educational background, and the overall safety culture of their organization.
Successful BEV deployment requires not only worker participation in safety planning but also enhanced training programs tailored to specific job requirements. Active engagement strategies should be employed to build trust and encourage open communication about emerging risks.
Research indicates that the successful implementation of safety measures depends not only on technological readiness but also on personnel preparedness. Cultivating a positive safety culture, establishing regular risk communication mechanisms, and demonstrating organizational support are crucial for raising risk awareness and ensuring compliance with new procedures.
While battery-powered vehicles (BEV) are widely favored for their environmental and health benefits, the evolving risk landscape requires continued investment in adaptive safety systems and the professional development of mine personnel to effectively protect worker well-being and operational safety.
New Advances in Battery-Powered Mining Technology
Recent years have seen significant breakthroughs in battery technology specifically designed for heavy-duty mining applications. The latest high-energy-density lithium-ion battery packs enable longer operating cycles and enhance safety features for mining vehicles and locomotives.
Mining companies are collaborating with battery manufacturers, equipment original equipment manufacturers (OEMs), and technology companies to advance pilot projects and research and development.
Rio Tinto’s Oyu Tolgoi gold mine in Mongolia is a prime example of these technologies in action.
The mine has successfully introduced BEVs into its underground fleet (including haul trucks and loaders) and completed operational trials. Equipment such as battery-powered anchor drills and 18-ton loaders are already in operation, supporting the transition to electrified mining equipment.
Operational and Infrastructure Challenges
Despite significant advances in new energy technologies, widespread adoption of BEVs in the mining industry remains challenging. Key issues lie in battery lifespan and durability—particularly maintaining stable performance in the harsh operating conditions of mines.
Recent industry research emphasizes the need for batteries to maintain performance during intensive operating cycles.
The high initial capital investment in electric equipment and the necessary infrastructure upgrades (such as charging networks and power storage systems) have also made some operators cautious about transitioning.
Operational challenges are equally important: efficient energy management and charging scheduling are crucial for minimizing downtime.
Mining productivity is directly dependent on the availability of charging and battery swapping facilities, highlighting the importance of investing in advanced site planning and power management systems.
Furthermore, training mine operators and maintenance personnel in electric mining vehicle technology is crucial. Addressing these challenges requires a collaborative effort among companies, technology providers, and government agencies through research, incentives, and training programs.
Battery-Powered Vehicle Application Cases
In the past two years, the high-profile deployment of BEVs in the mining sector has provided concrete examples of industry progress:
Boliden, Epiroc, and ABB in Chile collaborated to introduce a fully battery-powered wireline assist truck system at the Chuquicamata copper mine. This system improved emissions and operating costs while setting a benchmark for similar projects worldwide.
The Oyu Tolgoi project in Mongolia demonstrates that through careful planning and the integration of multiple BEV models, the dual goals of safety and productivity can be achieved.
Industry data shows that most mines are choosing a phased transition: starting with assist vehicles and gradually moving to core load-and-haul systems. As the technology matures and infrastructure needs become clearer, early experience can effectively accelerate deployment and minimize the risks and trial-and-error costs of equipment upgrades.
The Future of Electrification in Mining
The ongoing transition to electric mining equipment is opening a new path for safer, cleaner, and more efficient mining operations. Recent institutional research, industry feedback, and real-world cases demonstrate the tangible environmental, economic, and health benefits of battery-powered equipment.
Thanks to larger batteries and faster charging technologies, these electric machines are now capable of handling a wide range of high-intensity mining tasks. Increasingly stringent environmental regulations and public demand for greener mining practices are driving continued investment in this technology.
Admittedly, barriers such as high upfront costs, the need for new infrastructure, and the need for skilled personnel remain. However, with deepening industry collaboration and the emergence of new solutions, these challenges are being overcome.
With the continuous advancement of power batteries and digital technologies, fully electric mining operations are becoming increasingly feasible and attractive. In the near future, we will undoubtedly see more fully electric equipment active in all aspects of mining production, becoming a key force in the industry’s equipment upgrades.
