| Written by Mark Buzinkay
Table of contents:
- Why does electrification in mining matter?
- Safety: Is electrification in mining a good thing?
- Electrification in mining: Industry initiatives
- FAQs
- Takeaway
- Glossary
Why does electrification in mining matter?
Electrification in the mining industry matters because it addresses several of the sector’s most pressing challenges at once: safety, sustainability, operational efficiency, and long-term economic viability. Mines, particularly those operating underground, have traditionally relied on diesel-powered equipment such as load-haul-dump machines and haul trucks. While robust and proven, diesel machinery introduces significant drawbacks, most notably emissions of exhaust gases, high heat loads, and the consequent need for massive ventilation systems. These systems are not only costly to install and operate but also energy-intensive, accounting for a large share of an underground mine’s total power consumption. Electrification removes or drastically reduces these exhaust emissions and heat sources, enabling operators to scale down ventilation and cooling infrastructure. The result is a direct reduction in both capital and operating expenses, while simultaneously creating a healthier, safer work environment for miners.
The environmental dimension is equally compelling. Mining companies are under mounting pressure from regulators, investors, and host communities to reduce their carbon footprint and align with global commitments to net-zero emissions. Diesel fleets represent a substantial portion of a mine’s Scope 1 emissions, making electrification one of the most direct levers for decarbonisation. Beyond corporate responsibility, there is a reputational and financial incentive: companies that move faster towards low-emission operations can secure a stronger social license to operate, attract environmentally conscious investors, and access capital under more favourable terms. For commodities like nickel, copper, and lithium—which themselves are essential to the energy transition—the optics of producing “green” or low-carbon minerals carry real market value, as downstream customers increasingly seek verified sustainable supply chains.
Electrification also contributes to productivity improvements. Battery-electric vehicles deliver instant torque and strong performance in challenging ramp environments, often matching or exceeding diesel machines in tramming and loading efficiency. Advances in battery chemistry, trolley-assist technology, and charging infrastructure now mean that productivity compromises are no longer inevitable. In fact, in many cases, battery-electric fleets can operate with equal or greater uptime, especially when paired with swappable battery systems or rapid charging solutions. The absence of exhaust gases in working areas reduces downtime related to air quality concerns, and automation systems integrated with electric equipment further amplify output by allowing for continuous operation in conditions that would otherwise require human withdrawal.
Worker health and safety is another key driver. Reducing diesel particulate matter and heat underground dramatically improves air quality and working conditions. This is not just a regulatory compliance issue; it directly influences recruitment and retention in a labour market where mining often struggles to attract skilled workers. Providing a modern, cleaner, and technologically advanced workplace becomes a differentiator for employers. Moreover, the reduced exposure to diesel exhaust mitigates long-standing health risks associated with underground mining, aligning industry practices with broader occupational health expectations.
Ultimately, electrification in mining is about future-proofing the industry. It is a strategic response to societal, regulatory, and economic pressures that are converging on resource extraction. Those who adopt electric technologies early are likely to gain an operational and reputational advantage, while those who delay may face escalating costs, limited investor confidence, and tighter regulations. Electrification, then, is not simply a technological shift—it is becoming a defining factor in the competitiveness and sustainability of the global mining sector.
Safety: Is Electrification in Mining a Good Thing?
Safety is one of the most persuasive arguments for electrifying underground mining operations, and its benefits extend well beyond the well-known improvements to worker health. By eliminating diesel engines, electric equipment removes two major hazards: exhaust emissions and heat. Diesel particulate matter is a proven carcinogen, and reducing it from underground environments significantly lowers the long-term health risks for miners. At the same time, less heat generated by engines and exhaust means that ambient temperatures remain more manageable, reducing the risk of heat stress and allowing crews to work in safer, more comfortable conditions. These factors directly influence day-to-day safety, but they also have major implications in emergency scenarios. In the event of a fire or ventilation failure, the absence of diesel fumes and lower overall heat loads can slow the deterioration of air quality, buying precious time for evacuation and improving survivability (see also: Safety training). Cleaner, cooler air also enhances the effectiveness of refuge stations and reduces the likelihood of secondary hazards such as smoke inhalation, which is often a leading cause of injury during underground incidents.
Another important aspect is operational visibility. With electric fleets, less dust is stirred up by hot exhaust currents, which can otherwise obscure vision and complicate machine operation. Reduced noise levels also improve situational awareness, enabling operators to hear alarms, communication systems, or even approaching equipment. These environmental improvements create a safer working rhythm and make emergency response more effective. Furthermore, the integration of electric machines with advanced mine monitoring and automation technologies allows for remote operation in hazardous zones, meaning that fewer personnel need to be physically exposed to risk in the first place.
However, electrification also introduces new challenges. High-capacity batteries store vast amounts of energy, and while designed with multiple safeguards, they can present fire risks if damaged, improperly cooled, or subjected to thermal runaway. This means fire suppression systems, charging bays, and maintenance procedures must be rethought and upgraded. The handling of battery swaps or charging infrastructure also requires specialised training to prevent accidents, including electric shock or improper isolation. Mines must therefore adapt their safety protocols, emergency drills, and firefighting strategies to account for these new hazards. In sum, electrification significantly reduces many traditional underground risks, but it shifts the safety focus toward electrical integrity, thermal management, and rigorous operator training.
Electrification in mining: Industry initiatives
In a compelling exploration of the underground mining industry’s path toward net‑zero operations, Jonathan Rowland’s “It’s electrifying!” piece in North American Mining (May 8, 2025) argues that electrification has become not just desirable, but inevitable. The article unfolds as an in-depth dialogue with industry leaders—from ABB to Caterpillar, Epiroc, Komatsu, and Sandvik—highlighting concrete advances in electric load‑haul‑dump (LHD) technology and supporting infrastructure.
ABB’s narrative roots in early innovation, tracing back to their 1980s work with the Kiruna Electric System, set the historical stage. The company emphasises that electrification in mining isn’t new—what has changed is recent acceleration, largely driven by net‑zero commitments. Their most striking milestone: in collaboration with Boliden and Epiroc, ABB implemented the first fully battery‑electric trolley‑truck system on an 800‑meter underground test track in Sweden. Combined with promising findings from the Cosmos study (a pre‑feasibility analysis at the Cosmos nickel mine in Western Australia) that demonstrated BEV fleets can match diesel in productivity, bring lifecycle cost parity, and yield energy savings through reduced ventilation needs, ABB showed the all‑electric mine is within reach.
Caterpillar offers a dual‑track approach. On one hand, its R1700 XE is a fully battery‑electric loader featuring fast onboard charging via the MEC500 charger—capable of fully charging in under 30 minutes, or under 20 with two units. On the other hand, the company introduces the RC2900 XE, a diesel‑electric hybrid with superior breakout force and reduced parts, designed to offer immediate electric-like performance and lower TCO while serving as a bridge where full electrification isn’t yet feasible.
Epiroc emphasises versatility and scalability. Its BEV fleet includes ST14 and ST18 Scooptram loaders and the MT42 Minetruck, prominently featuring swappable battery packs to maximise uptime. In addition, the MT42 trolley‑assist variant allows connection to a catenary system on steep ramps, and the MT66e serves as a diesel‑electric interim solution where diesel engines power wheel‑hub motors, delivering 8‑10% fuel savings and ramp‑speed advantages.
Komatsu, meanwhile, focuses on practical infrastructure improvements. It has developed the WX04B loader with a ground‑level, quick‑swap battery system—no cranes required—with an onboard tram battery permitting machine repositioning without external power. Their portable 150 kW charger minimises fixed installations. With internal tests showing four‑hour runtimes and a mid‑2025 planned commercial release, Komatsu underscores safety and uptime via thermal‑managed packs and structural protection.
Sandvik rounds out the ensemble with automation and speed. Their Toro LH518iB is an 18‑ton BEV loader capable of autonomous operation and “AutoSwap” battery replacement in about five minutes. Developed and tested in their Tampere facility and customer sites, it pairs with a roadmap toward larger automated BEV trucks—demonstrating Sandvik’s strategic push into electrified, intelligent fleets.
FAQ: Electrification in Mining
Why is electrification important for underground mining?
Electrification reduces harmful diesel exhaust and heat, which improves air quality and lowers ventilation requirements—one of the biggest costs in underground mines. It also supports corporate sustainability goals by cutting carbon emissions and helps mines meet stricter regulatory and investor expectations. Cleaner, quieter equipment creates safer, healthier conditions for workers while positioning operators to supply “green” minerals that are increasingly in demand.
Does switching to battery-electric equipment reduce productivity?
Modern battery-electric vehicles (BEVs) have reached parity with diesel in many cases. Advances in swappable battery systems, fast charging, and trolley-assist technologies mean uptime and tramming speeds can equal or even surpass diesel fleets. In addition, lower downtime from ventilation constraints and better integration with automation systems can improve overall productivity. While charging and infrastructure require planning, long-term studies show that lifecycle costs are comparable to diesel, with added benefits in ventilation savings.
What are the new safety considerations with electrification?
Electrification eliminates diesel particulate matter and reduces underground heat, improving baseline safety. In emergencies, the absence of exhaust fumes slows air quality deterioration, providing more evacuation time. However, large battery packs introduce new risks, such as thermal runaway or electrical hazards. Mines must therefore implement robust thermal management, specialised fire suppression, and enhanced training for battery handling. With proper systems in place, the overall safety profile of an electrified mine is stronger than traditional diesel operations.
Takeaway
The shift to electrification in mining represents far more than a technological upgrade; it is a decisive step toward safer, cleaner, and more efficient underground operations. By reducing exhaust emissions and heat, electric fleets not only cut ventilation costs but also create healthier conditions for workers, while aligning mines with investor and regulatory expectations around sustainability. Yet the value of electrification also lies in its role as a new layer of risk management. In emergency scenarios such as fires or ventilation failures, lower heat loads and the absence of toxic diesel fumes extend the critical window for safe evacuation, enhancing overall mine resilience. At the same time, electrification introduces fresh risks associated with high-capacity batteries, thermal stability, and electrical safety. To fully realise the benefits, operators must invest in advanced thermal management, upgraded fire suppression, and comprehensive staff training. In doing so, mines turn electrification into both an operational advantage and a strategic safeguard for the future.
Delve deeper into one of our core topics: Mining safety
Glossary
Thermal-managed packs are battery systems equipped with integrated cooling and heating mechanisms designed to keep cells within an optimal temperature range during charging, discharging, and idle states. Effective thermal management prevents overheating, uneven temperature distribution, and thermal runaway—critical in demanding environments like underground mines where high loads and ambient heat are common. Techniques include liquid cooling, air circulation, and phase-change materials, all of which extend battery life, improve performance, and enhance operational safety. (2)
References:
(1) https://northamericanmining.com/index.php/2025/05/08/its-electrifying/
(2) Zhang, J., & Lee, J. (2011). A review on prognostics and health monitoring of Li-ion battery. Journal of Power Sources, 196(15), 6007–6014. https://doi.org/10.1016/j.jpowsour.2011.03.101
Note: This article was partly created with the assistance of artificial intelligence to support drafting. The head image was generated by AI.
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