MINING TRUCKS
with Penske Australia & New Zealand, the exclusive distributor of Rolls-Royce Power Systems’ mtu engines and power solutions to mining in that region.
The system combines proven mtu Series 4000 engines with a high-performance electric drivetrain. Depending on the topography and operational profile of the mine, this can result in savings of up to 30 % in fuel consumption and CO₂ emissions compared to conventional drive systems.
Rolls-Royce Solutions Chief Engineer, Hybrid Mining Truck, Alexander Richter presented the development concept at The Electric Mine conference on 7 May 2026 in Lisbon, Portugal. He highlighted the experience of the company from extensive repowers in the industry:“ We consider a hybrid retrofit as basically taking repowers to the next level... our worldwide organisation, our distribution network, is fit and capable to execute repowers at a high quality level.”
He said therefore it has the facilities and staffing power to offer hybrid conversions with its existing network- plus the company already has hybrid solutions in the marine and rail business. For mining trucks, over the past few years Rolls-Royce has developed its hybrid concept into an optimised layout for a baseline testing campaign. The vehicle integration into a mining truck was underway in May in tandem with hardware functionality validation and verification on a loop test stand.
In the mtu hybrid, the OEM powertrain with all safety functions remains fully intact to reduce cost and complexity. The hybrid control system with battery and DC / DC converter that matches the battery and link voltage plus controls the energy flow, and the thermal management system- all are integrated as a subsystem.
As with other hybrid systems, it stores the haul truck’ s braking energy in batteries during downhill journeys. This energy is then used to drive the wheel motors during the subsequent uphill journey. As a result, the diesel engine operates under a lower load – and consumes significantly less fuel. At the same time, CO₂ emissions are reduced. The aim is a modular, scalable system that can be adapted to different vehicle types, mine topographies and operating conditions.
“ Transport in open-pit mining using haul trucks accounts for the largest share of production costs – and a significant proportion of emissions. Hybrid drive systems offer an effective lever for cost reduction and decarbonisation here,” said Cobus van Schalkwyk, VP Global Mining at RRPS.
For decades, mtu diesel engines have been reliably powering vehicles for openpit mining: from blast hole drilling rigs to excavators and wheel loaders, right through to haul trucks and other mining machinery, whether diesel-mechanical, diesel-electric or diesel-hydraulic.
The engines of the mtu Series 4000 were developed for powerful, versatile and, at the same time, efficient continuous operation. Furthermore, the key variants are approved for use with the sustainable fuel HVO( hydrogenated vegetable oil) which already enables a significant reduction in their carbon footprint.
Thiess, FLANDERS and a holistic hybridisation pathway
Global mining services company Thiess recently published its 2025 Sustainability Report, in which it says it continues to refine its pathway to emissions reduction,“ acknowledging that commercially viable technologies capable of powering large mining fleet to achieve net zero emissions are still in development.”
It says the broader energy transition is advancing at a slower pace than anticipated, driven by rising global energy demand, delayed deployment of enabling infrastructure and the technical challenge of broad-scale diesel displacement.
The Thiess Group, however, recognises its position in providing mining services for a lower-carbon future, and its responsibility in helping enable the energy transition.“ We acknowledge the current constraints associated with the operation of a fully electric or hydrogen powered mining fleet and are focused on supporting our clients with economically viable decarbonisation pathways.”
In 2025, Thiess continued investigations into decarbonisation solutions, however, it sees a gap between industry decarbonisation targets and the likely timeline for viable commercial implementation of lower-emissions mining solutions. Therefore, Thiess Group is focusing on interim technologies to bridge this gap. And a key focus area is agnostic hybrid solutions to suit existing diesel and diesel-electric mining equipment.
Thiess:“ Agnostic hybrid solutions offer the ability to technology-stack with other market solutions as these become commercially available. The current industry preference to extend the life of assets through zero hour rebuilds offers Thiess an opportunity to install hybrid kits on OEM trucks while completing rebuilds for our business, existing clients and broader markets.”
In 2024, Thiess entered a Memorandum of Understanding with FLANDERS to focus on delivery of diesel-mechanical hybrid retrofits as a current cost-effective emissions reduction solution. In 2025, Thiess and FLANDERS progressed their mechanical hybrid retrofit initiative, completing key elements of installation planning, risk assessment, compliance reviews and detailed trial design.
In broad terms, the FLANDERS Hybrid Haul Truck Drive System is a modular, retrofit drive system designed to enhance performance, efficiency and emissions reduction objectives for existing haul trucks, regardless of the OEM. It is equipped to receive power input from multiple sources, including combustion engines, batteries, hybrids, trolley systems and hydrogen fuel cells. The mechanical truck upgrade combines this drive system with a specially designed electric motor. The drive cabinet is liquid-cooled, dust-proof, and compact, fitting seamlessly onto mining trucks without obstructing visibility from the cab. FLANDERS’ engineering teams designed everything in house including the hardware and the firmware and the power electronics.
At The Electric Mine 2026 conference in May in Lisbon, Joy Mazumdar, Global Vice President of Technology Engineering at FLANDERS outlined the process in a joint presentation with Thiess – coupling the new hybrid motor to the torque converter; shortening the drive shaft; adding FLANDERS’ liquid cooled drive system( inverter, DC / DC, batteries, FREEDOM controls); and interfacing with existing truck controls. For diesel electric drive trucks, a process involves adding the FLANDERS liquid cooled drive system( dual inverter, DC / DC, batteries, FREEDOM controls); plus addition of a new gridbox with AC blower; and again interfacing with the existing truck controls.
Together in 2025, Thiess and FLANDERS developed a trial to test hybrid retrofit technology on a Cat 793D haul truck in New South Wales, Australia. They aim to collaboratively install the hybrid kit in 2026, then to run it for a trial period to validate asset performance and product viability. Pending successful trial outcomes, the team proposes to implement the technology on a full production circuit of trucks in Queensland to demonstrate industry benefits.
Pre-trial modelling indicates fuel consumption and emissions should be reduced by approximately 16 %, equating to 360 tCO 2-e saved per year per 230-tonne class truck. Additionally, the technology should provide an increase in maximum speed and acceleration. Under suitable project conditions this should result in improved cycle times. Thiess:“ The aim is to provide this bridging technology to our customers until a full battery-electric solution becomes commercially available.”
Also at The Electric Mine 2026 in Lisbon, Thiess’ s Senior Specialist, Asset Decarbonisation Cameron Lynn outlined in more detail in the joint presentation with FLANDERS the significance of this project in
52 International Mining | JULY 2026