Ben Ting, Chief Commercial Officer for Echion Technologies delves into the abundance of benefits afforded by the use of hybrid technology in the mining sector, paving the way for increased decarbonisation.
ACCELERATING DECARBONISATION THROUGH HYBRID TECHNOLOGY
The mining industry plays a crucial role in achieving mass electrification. The rapid rise in demand for the rare earth minerals that most battery technologies require has placed greater pressure on the industry to improve its productivity and efficiencies, but mining is also facing significant pressure to decarbonise its operations to meet global emissions targets.
Haul truck operations, for instance, currently contribute significantly to global carbon emissions at around 68 million tonnes of carbon dioxide (CO2) per year, the equivalent greenhouse gas (GHG) footprint of Finland or New Zealand, according to Rocky Mountain Institute.
Therefore, choosing the right solutions to enable mines to run as cleanly and cost-effectively as possible is a major challenge for mine operators. However, emerging, innovative battery technologies are unlocking the possibility for hybrid-electric haulage trucks that offer a practical solution for industry decision-makers as they seek to transition towards full electrification.
The majority of mining sites are located in remote areas, which often presents challenges of limited grid capacity and a lack of charging infrastructure.
Although fully electric vehicles (EVs) could offer substantial reductions in emissions and the high cost of vehicles, significant upfront investment would have to be made in the supporting infrastructure to enable full integration in operations.
For many operators, the capital required to invest in both new vehicles and charging networks is not practical, but by combining advanced battery chemistry with conventional diesel systems, a potential move to hybrid technology can become a more viable near-term solution.
HARNESSING THE POWER OF HYBRID
The recent advancements in battery technology, such as Echion Technologies’ (Echion) niobium-based anode material XNO® – which was specifically designed with industrial applications in mind – mean that hybrid haulage trucks are now a true possibility.
Standard lithium-ion batteries used in most passenger vehicles require a long time to fully charge but, when used in lithium-ion cells, XNO® offers outstanding performance characteristics that far outperform current mainstay batteries when applied in heavy-duty applications.
These include rapid charging, an extended cycle life of more than 10,000 cycles, and market-leading safety attributes. These benefits are critical in mining operations where reducing downtime and improving operational reliability are paramount.
In the demanding, hot, and humid underground conditions where mining trucks operate continuously, current ‘off-the-shelf’ batteries cannot provide the significant volumes of sustained power required for performance or safety, making efficient and safe hybrid mining vehicles a previously unviable option.
NEXT-GENERATION TECHNOLOGIES
This changed in 2024 when we demonstrated the benefits of utilising our niobium-based anode technology through a collaboration with Switch Technologies. This saw the retrofitting of a mining workhorse vehicle, a Toyota Land Cruiser 79 Series, into a hybrid vehicle.
Although testing and refining are still ongoing, through our joint approach to collaboration and development, we have produced a working prototype hybrid vehicle that we believe will be able to complete around 90 percent of a standard shift for a vehicle of its kind on battery power.
This has illustrated the power of XNO® when utilised in a hybrid vehicle and demonstrates its ability to provide rapid charging and reliable performance, even in remote mining conditions.
A hybrid option also offers operators greater assurance and levels of comfort in terms of range anxiety. The design of our hybrid Land Cruiser prototype allows for easy mode switching at the discretion of the operator.
This flexibility is key for mining trucks, which are required to perform continuously across multiple settings. An operator can choose battery mode when the conditions support rapid, or even regenerative charging, and diesel mode when longer range is needed.
As a result, mining fleets experience increased uptime and efficiency whilst still contributing to a significant reduction in operational emissions.
Crucially, the project presents a commercially scalable model for decarbonisation in mining. By enabling operators to retrofit existing vehicles rather than committing to full fleet replacement, hybrid technology is able to provide a more capital-efficient route to emissions reduction.
It also enables the flexibility for mining companies to extend the operational life of their assets, manage costs, and begin their electrification journey at a pace that aligns with the current infrastructure and operational priorities.
ONE STEP AHEAD
Whilst the long-term benefits of fully electric mining vehicles are clear, waiting for supporting infrastructure to catch up will delay progress in the move to decarbonise operations and mining sites.
The hybrid approach provides a strategic stepping stone for operators to take advantage of today. It will enable the industry to modernise its fleet and reduce its carbon footprint immediately, whilst the methodology, planning, and resources can only be considered for longer-term adoption of fully electric technologies.
The future of mining will be defined by innovation and collaboration. By utilising hybrid battery technology, industry decision-makers are able to move towards an essential milestone on the journey to fully electric, sustainable, high-performance operations.
