UNDERGROUND LOAD AND HAUL
KGHM ZANAM’ s HD14e 14-t payload battery-powered loader will be equipped with a lithium iron phosphate battery pack with an energy capacity of 585.6 kWh
– especially those with mature existing mines – it represents an interim solution on the route to net zero – offering emission wins today without mines having to go all in on battery-electric machines with a higher initial cost, plus associated charging infrastructure.
The carbon cut upside comes from combining a Cat C15 engine with a highefficiency electric drive system that lowers fuel burn by over 31 %, meaning lower exhaust emissions but also less heat, noise and vibration, plus reduced engine maintenance costs thanks to lower engine revolutions, Caterpillar claims. Maintenance and service intervals are also reduced thanks to fewer moving parts than a traditional torque converter.
It is widely expected that Caterpillar will also launch a diesel-electric drive underground mining truck, possibly based on the AD63, however, this has not been made public to date. Caterpillar’ s Paul Bitter, Product Value Stream Manager, told IM at MINExpo 2024 that it sees the XE platform having applicability for both loaders and trucks, where, because of the electric drive, you can change power source:“ This means you can have a diesel machine, a hybrid machine or a fully-electric machine.” He added the most likely haulage and loading candidates for the‘ XE treatment’ are machines that currently only come in diesel form, have not recently been updated and have large populations out in the field.
KGHM ZANAM progresses latest zero-emission solution
KGHM ZANAM S. A, one of the largest manufacturers of underground mining machinery in Europe and the principal equipment supplier to KGHM Polska Miedź
14
S. A, is consistently expanding its portfolio to, it says, redefine standards of underground work.
The KGHM ZANAM portfolio includes, among others, loaders, transport trucks, haul trucks, charging( explosives) vehicles, utility vehicles, roof bolters and rock scalers.
In recent years, particular emphasis has been placed on developing low- and zero-emission machines that respond to the growing demands of modern mining in terms of energy efficiency, workplace safety and reduced carbon footprint.
KGHM ZANAM’ s solutions have for many years been successfully operated in mines in Poland and across European markets. The company is now intensively expanding its international presence, focusing its efforts on North America, the Balkan states, the United Kingdom, Turkey and selected African countries. All these regions are characterised by rising demand for advanced technologies supporting the energy transition and the automation of mining processes.
One of the newest projects being delivered by KGHM ZANAM’ s Research and Development Department is a modern 14-t payload battery-powered loader designed for use in underground mines. The design marks a further stage in the company’ s development of zero-emission solutions and has been engineered to deliver high productivity while reducing operating costs and improving environmental conditions underground, the company says.
The machine being designed will be equipped with a lithium iron phosphate battery pack with an energy capacity of 585.6 kWh. This technology offers a high level of safety, resistance to intensive duty cycles, thermal stability and a long service life – all of which are critical in the demanding mining environment.
According to the analyses carried out and the design assumptions, the stored energy should provide between 3.5 and 4 hours of continuous loader operation, depending on the geological and mining conditions and the nature of the technological operations performed. The parameters of the power system have been optimised for maximum operating efficiency while maintaining appropriate tractive and working performance of the machine.
A key element of the project is the use of an automatic battery-swapping system. This solution will enable a depleted battery pack to be quickly replaced with a previously prepared and charged module, minimising machine downtime. In practice, this will help maintain high fleet availability and allow the loader to be returned smoothly to the production cycle without the lengthy stoppages associated with charging.
The company says:“ The development of electromobility in underground mining brings benefits that extend far beyond simply eliminating exhaust emissions. Electric drives help reduce the ventilation requirements of underground workings, lower noise levels and improve crew comfort and safety. At the same time, they enable greater energy efficiency across the entire mining process.”
KGHM ZANAM sees electromobility as part of a broader technological transformation of mining. The company, as part of developing successive generations of machines, is assessing the potential to implement remote-control systems that will allow operators to carry out work at a safe distance from the face. Looking further ahead, autonomous solutions are also being considered, drawing in part on experience gained during R & D projects relating to the automation and digitalisation of haulage processes in underground mines.
The company concluded:“ The new 14-t battery-powered loader represents another step by KGHM ZANAM in building a comprehensive offering of zero-emission machines for underground mining. The project also confirms the strength of Polish engineering and the company’ s ambitions for further growth in the global market for advanced mining technologies.”
Nordkust out to offer real haulage productivity
Having confirmed a battery-electric proof point on surface at LKAB’ s Svappavaara mine, Sweden-based SANY dealer Nordkust Maskin AB is now looking to follow a similar blueprint underground.
Johan Gustafsson, Founder & CTO, and Linda Dittrich, COO & co-Owner, took to The Electric Mine 2026 stage in early May to
International Mining | JULY 2026