Pioneering technology to electrify Japan’s mining industry

A global thirst for raw materials that power the energy transition has led to booming demand¹ for metals and elements to make batteries, motors, drives and other essential electrification components.

Metals including lithium, cobalt, nickel, copper, aluminium and manganese, along with conductive elements such as graphite, are more sought after than ever – a need which is making new demands of the mining sector.

Mining is an energy-intensive industry, responsible for up to seven percent of global greenhouse gas emissions². A large volume of these is attributed to diesel-driven vehicle movements in open-pit and underground mines.

Japan is home to a number of the world’s leading manufacturers of mining equipment, such as mining trucks, and we are collaborating with companies including Hitachi Construction Machinery, Komatsu and Sumitomo Corporation to help them achieve decarbonization and efficiency goals in this vital industry.

Testing world’s first ultra-large electric haul truck

Since 2021, ABB and Hitachi Construction Machinery have jointly developed the world’s first ultra-large fully electric haul truck. It was shipped to Zambia’s Kansanshi copper-gold mine during 2024, where it has undergone trials over subsequent months.

These are the world's first³ technological feasibility trials of an ultra-large full battery haul truck by an OEM (Original Equipment Manufacturer) at a customer’s mining site.

The trials are being conducted to support Hitachi Construction Machinery’s goal of transforming its trucks from diesel to full battery operation, using our high-performance traction battery and highly energy-efficient DC/DC converters.

On level ground, the truck runs on its internal battery, then, 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 running downhill, the truck’s regenerative braking system charges the battery, reducing the charging load when the truck is 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.

A sophisticated battery energy and thermal management system maximizes service life of the batteries.

Partnering with Komatsu to find decarbonization solutions 

A further collaboration is designed with Japan’s Komatsu – one of the world’s largest providers of construction and mining machinery – to jointly create electrification and decarbonization solutions, ranging from renewable energy generation to fully electrified mining equipment for customers, through an open platform.

Both companies are committed to accelerating decarbonization in mining, and have established a joint team to develop and bring to market integrated solutions that will help reduce diesel consumption and ultimately eliminate it through the electrification of mine operations. ABB’s contribution to the collaboration will be in the areas of automation and electrification.

Sumitomo and ABB to explore decarbonization of mining machinery 

Building on our collaboration with Komatsu, we have entered an agreement with Japan’s Sumitomo Corporation, designed to establish strategies and recommendations for technology systems in heavy industrial applications, such as mining.

We’re working with Sumitomo’s Construction and Mining Systems Strategic Business Unit, to explore joint solutions for decarbonizing the operations of mining machinery, with a focus on fleet electrification and renewable power integration.

Sources:
1. IEA: The role of critical minerals in clean energy transitions
2. Climate risk and decarbonization: what every mining CEO needs to know 
3. As of June 27, 2024, based on a survey conducted by Hitachi Construction Machinery of ultra-large dump trucks with a load capacity of 150 tons or more manufactured by OEMs

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