Rethink the equipment so the customers can keep the same mine

In this interview, Brian Huff, Vice President of Technology, Battery and Hybrid Electric Vehicle Business Unit, Sandvik Mining and Rock Solutions, discusses the exciting developments surrounding battery electric vehicles (BEVs) and the implications for mining fleet electrification.

ENERGY AND MINES: With diesel consumption from large mining vehicles accounting for up to 60% of a mine’s carbon footprint, there is real urgency for miners to identify the solutions for decarbonizing heavy-haulage trucks and equipment. Can you tell us about Sandvik’s approach to supporting mining’s transition to zero-carbon heavy haulage and equipment?

BRIAN HUFF: Sandvik is committed to electrification across all mining divisions and is working on multiple fronts to decarbonize mining equipment. The first electric loader was launched in 1981 and the 600th unit was delivered in 2019. The first Sandvik electric truck was produced in 1988. Sandvik currently offers electric solutions (both battery and tethered) for drill rigs as well as load and haul equipment with a broad range of available models to choose from and our ambition is to have a full range offering by 2025.

Battery technology has enabled untethered equipment that exceeds the capability of its diesel predecessors. Sandvik is designing equipment that capitalizes on the benefits of electrification in terms of performance and utility without impacting infrastructure. Technologies like AutoSwap and AutoConnect allow operators to swap batteries in just a few minutes without leaving the cabin and without the need for overhead cranes or other complex or expensive infrastructure. The depleted battery can then be charged at lower power to prevent a dramatic impact on the electric grid. The quick and easy “refueling” of the machine further reduces the demand for large, heavy, high-capacity batteries, and the slow charging benefits both the mine infrastructure and helps the battery last longer. Recently there’s been an increase in interest and viability of battery-electric products,

Sandvik is running a 100MWh battery factory and is committed to engineering the industry’s only battery system designed 100% for mining requirements only. Last but not least, we are investing in infrastructure (facilities, inventory), training and people to deploy and support new zero-carbon technology locally around the world

E+M: What are some of the latest developments in terms of technology readiness and commercialization for electric trucks and equipment?

BH: Sandvik acquired Artisan in 2019. The combination of Artisan’s battery technology and Sandvik’s decades of experience in engineering and manufacturing accelerated our work in the battery electric vehicles (BEV) space.

We are now working on the second iterations of our batteryelectric loaders and trucks, including LH518B, TH550B, and TH665B, which incorporate the best of Artisan’s battery swapping technology and Sandvik’s expertise in engineering. Many customers are still trialing BEVs with a single-vehicle investment to familiarize themselves with the technology. However, we are encouraged that mining industry leaders, including Newcrest Brucejack, New Gold New Afton, Foran McIlvenna Bay, and BHP Jansen, are conducting their own independent evaluations and graduating to full fleets with our proven technology.

E+M: What are the main challenges for accelerating and commercializing zero-emissions mine trucks and equipment?

BH: Though zero-emission products are still new and rapidly evolving, more and more machines are now working in full production environments; we are, therefore, well past the experimental phase. However, it is still an ‘early adopter’ situation, and some miners are choosing to wait for fully tested, proven, and predictable zero-emission equipment. These customers are hoping to gain confidence from success stories in mining electrification before they commit their mobile fleets to this new technology.

The more case studies are available, the more confident mines would be about BEVs and their beneficial impact on operating costs and productivity. News of their successful deployment will emerge more rapidly now that more mines are making the shift to electrification, and this would, in turn, build the industry’s confidence in the technology.

However, because BEV technology is new to the mining industry, many customers struggle to understand its performance potential, and other issues including operating cost, servicing the equipment, safety, operating procedures, and training. Clearly, there is an amount of hard work that must be done to analyze and model zero-emission versus conventional fleets. In this regard, Sandvik is investing a lot of resources in documentation and tools, and training employees to assist customers with technical information and knowledge.

E+M: Can you tell us about some of the exciting projects Sandvik is working on with mining clients in this area?

BH: We are working on several exciting projects here in Canada. We are currently in the process of deploying BEVs at the Newcrest Brucejack mine, soon to become one of the largest and most modern BEV fleets in the world. We also recently announced a partnership with Foran Mining for their McIlvenna Bay project in Saskatchewan. Designed to be the world’s first carbon-neutral copper development project, it will supply zero-carbon copper for wind turbines, solar panels, and other technologies required in the green revolution. Foran has committed to a complete battery electric fleet including loaders, trucks, and drills, which is the first time we have seen a mine do that.

Sandvik will also deliver several battery trucks to the British Columbia market, as well as a full fleet of battery loaders to the BHP Jansen project in Saskatchewan.

Although Canada is a front runner in BEV adoption, and the Canadian BEV market is growing incredibly quickly, Australia and Europe are not far behind. We are supporting the transition in these markets with customers including Agnico Eagle, Gold Fields, Boliden, LKAB, Barminco, and Byrnecut.

E+M: What is needed to support the business case for mining making the transition to low-carbon alternatives?

BH: Markets around the world have widely differing conditions relating to energy, and this makes it challenging to define a universal business case applicable globally. However, regardless of the jurisdiction, there are powerful arguments in favor of the move toward battery electric fleets, including better management of the mine’s energy composition, reducing its impact on the surrounding communities, or an improvement in the productivity of its fleet. There could, therefore, be many different approaches to the business case for transiting to a low-carbon regime. Moreover, mines could further enhance this business case (one that is arguably good already!) with some proactive steps.

First, mines need to “expect more.” By fully harvesting the productivity potential of electric fleets, which are often capable of moving 20-30% more tonnage per day thanks to their higher power and speeds, mines should fully capitalize on such a superior performance from electrified equipment. Secondly, mines should operate and maintain batteries in a way that maximizes their life. Proper maintenance, temperature management, depth of discharge, and charge rate reduction can make a big difference in the economics of batteries because these are the new consumable “fuel” for electrified equipment. Lastly, extraneous factors such as a high diesel price and a value on carbon (e.g., through taxes and incentives) may further enhance the allure of decarbonizing fleets.

E+M: What are some of the key considerations for miners considering fleet electrification?

BH: First, our overall design principle is to rethink the machine, not the mine. What that means is we design zeroemissions technology that can be deployed in existing mines and supported by existing maintenance organizations. We don’t believe in marketing technology that requires customers to redesign their mines and change their people and methods.

A major benefit of electric technology is the potential for significantly higher speeds. To get the full value out of fleet electrification miners, therefore, need to factor in how to handle a faster and higher output ore flow, as well as consider downstream logistics, crushing, and processing capabilities. It is important to have a clear understanding of the mine’s infrastructure limitations. For example, if there is a problem in adding load to charge batteries due to a limitation in electrical power capacity, one solution is to reduce the vent power consumption to offset the new load. Sandvik’s battery swapping technology is ideal for such cases because the charging power draw can be spread out over a longer period, thus limiting the peak power demand.

Additionally, a well-thought-out mine design can really amplify the benefits of BEVs. Sandvik’s batteries will recharge using regenerative braking when the vehicle is tramming downhill, so any opportunity where the vehicle can tram downhill while loaded will allow reductions in the use of charging energy.

E+M: What would you advise a mid-tier mining company looking to assess the various fleet decarbonization options but without the resources or budgets of a major mining company?

BH: Reach out to Sandvik. We have many tools and a lot of information that we provide free of charge. We see it as our responsibility as a leading OEM to help drive and support the overall transition. Many mining companies are evaluating BEVs right now, which is fantastic for many reasons including that mining engineering firms and consultants are rapidly building their knowledge in this area. Many of these firms would be able to complete a more comprehensive evaluation. At a more basic level, it is incredibly impactful and informative to see this technology with your own eyes. You can feel the difference in ambient temperature, you can hear how quiet the machine is, and you can see how powerful it is. The best way to learn is to visit a mine and/or one of our factories producing BEVs and see one for yourself.

Brian Huff is speaking at the Energy and Mines Toronto Summit, Nov 1, 4:50 pm, on the panel Mine Electrification: Technology Availability and Readiness

REPLACE OR REDESIGN? RETHINK.

TH550B is Sandvik’s first fully battery powered dump truck with a combination of proven solutions: 50 years of experience developing underground mining equipment by Sandvik powered by the Artisan™ battery pack.

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