MINING TRUCKS
of electrical interface solutions for the industry, with this latest innovation forming a key part in achieving this ambition. It says the Robot ACD will allow for more reliable and efficient truck charging without the need for human intervention. The fully automated, interoperable connection device is ruggedised to withstand the harsh environmental conditions of mines.
Allowing for a seamless transition into existing mining operations, the technology’ s scalability and interoperability means it will be compatible with current and future mining trucks, connection mechanisms, and interfaces.
This versatile system fully automates the charging process, maximising uptime with the highest power deliveries while keeping personnel out of harm’ s way. Video ABB
The technology was initially tested at ABB’ s laboratory in Sweden, which was followed by testing under real mining conditions at Boliden’ s Aitik site. ABB said at The Electric Mine 2025 conference in Santiago that it had achieved over 3,000 successful connection cycles, reaching a 98 % success rate and continuously improving. This is all the more impressive given the Arctic climatic conditions at the operation.
Hitachi and ABB advance Kansanshi battery trolley project
Also at The Electric Mine 2025, Hitachi Construction Machinery and ABB updated the audience on progress with battery trolley at the Kansanshi copper mine in Zambia. Since 2021, the two companies 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 first 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 ABB’ s highperformance 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.
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A sophisticated battery energy and thermal management system maximises service life of the batteries.
In a recent interview by HCM, the company also interviewed key members of the operator First Quantum’ s team on the project. Renewable energy accounts for 92 % of the power supply in Zambia. In addition to hydroelectric power, sources are likely to expand to solar, wind, and biogas in the future. Copper is indispensable as a component for electric vehicles, and more generally for realising a decarbonized society. The Zambian government has set a target of tripling copper production in the next few years.
“ If this project succeeds, we will be able to achieve that goal,” says Rees Magrath, Mining Operations Manager.“ Thanks to this technology, we greatly improved the speed of ramp climbing. This reduced fuel consumption, extended engine life, and reduced CO 2 emissions.”
The partnership between First Quantum and Hitachi Construction Machinery began 12 years ago through their collaborative development of trolley assist technology. Since then, the partnership between the two companies has grown stronger, leading to the current technological feasibility trial.
“ We are very similar to Hitachi Construction Machinery in terms of management philosophy and culture- in that we are always pushing technological progress and striving for improvement,” said Magrath.
“ The truck can move more quickly and efficiently. This allows us to reduce the use of diesel trucks and helps reduce carbon emissions. It’ s an incredible system that’ s really unique,” says Chief Mining Engineer, George Nzoma.
Mine Maintenance Manager, Gregory Mwansa adds that the truck also ensures worker safety:“ It’ s difficult for truck operators and workers in the area to sense danger because they’ re always exposed to noise. But a full battery rigid dump truck has no engine, so workers can always hear even low-volume sounds. This lets them to work with greater peace of mind.”
Superintendent, Charl Vermaak is confident:“ If this full battery rigid dump truck is a success, I think everyone will want to buy one. The world clearly has its eye on this project.”
The technological feasibility trial is continuing. The trolley assist lines at Kansanshi will double in the next 12 months and triple over the next five years. This is more directionally accurate relevant to First Quantum’ s current business plan.
The growing scale of trolley at FQM, and it has trademarked its Quantum Electra- Haul™ trolley-assist technology, was also referenced in First Quantum’ s 2024 ESG
Report.“ Our Quantum Electra-Haul™ trolleyassist technology reflects our commitment to innovation and sustainability, delivering practical solutions with measurable on-theground impact. Reinforcing this commitment, we are investing an additional $ 200 million to expand our fleet to 102 EH4000 Hitachi trucks, which will be fully operational by 2025. These trucks are power source agnostic, offering the potential for future battery conversion, and are trolley-assist compatible. With greater capacity and improved fuel efficiency, they enable a smaller fleet size while reducing emissions. This investment underscores our dedication to advancing the technology needed to decarbonise mining operations through pit electrification.”
FLANDERS FREEDOM for haul trucks
Thiess’ s agreement with FLANDERS will make it the FREEDOM for Haul Trucks launch customer – the system is an OEM agnostic retrofit-friendly solution for lower emissions based on its AC motor technology which can be integrated into both mechanical and diesel-electric trucks. What synergies are there between the companies? Wayne Chmiel, Global President of Technoogy Solutions at FLANDERS told IM in February:“ Mining is a cost competitive business, and we sought a partner that is focused on producing at the lowest costs. Our hybrid solution is a decarbonisation solution for sure, but more importantly it is a cost improvement solution and we sought out Thiess as they are the lowest cost producer in the market. Together we have a very clear and common collaborative vision for reducing mining fleet emissions, but profitably, which has been the case right from my initial meetings with Thiess VP Operations North America, David Perkins. We also have very complementary offerings – both companies are very good in the segment they operate in. Thiess’ s skill set is running mining equipment efficiently and at the lowest cost per tonne for clients, while FLANDERS leads the industry in advanced drive solutions, technology, automation, and retrofitting capabilities across any OEM.”
So how will the FREEDOM for haul trucks collaboration proceed from here? Chmiel:“ We have talked about conversion of trucks, both diesel electric and mechanical drive. Thiess has over 3,000 pieces of equipment so there is no shortage of candidates, but we have narrowed things down to a few different truck models that keep coming up. We are having strategy sessions and looking at both the North American market, as well as their operations globally.”
Once the initial conversions are carried out and proven, Thiess will ultimately carry out the conversions to the FREEDOM for
International Mining | JULY 2025