BATTERY AND ELECTRIC VEHICLES
The cement mine, located in Kocaeli- Körfez, east of the Marmara region surrounding Istanbul, is positioned in such a way that the trucks travel downhill, fully loaded, on an average grade around 10-12 %. Regenerative braking enables the truck to recharge its battery as it descends and, once unloaded, ascend to the top of the mine using only previously regenerated electric power.
There are certainly no one-size-fitsall solutions when it comes to hybrid projects, with different sized batteries and configurations being weighed by the interested companies, according to Berthold, mentioning that the work it is carrying out with contract miner U & M in Brazil is a case in point.
“ On some of the older truck retrofit projects we have looked into there is a big
The First Mode retrofit kit, delivered by Cummins, has been fitted on a Komatsu 930E truck( number 330) at Caserones
“ There are not many sites that boast this same type of topography to generate the substantial energy regenerative from downhill braking,” he told IM.
China’ s HATL also recently converted two Euclid EH1700 trucks to battery operation as the EH1700E for Nuh Cement as part of its Mission Zero program.
The potential applications to apply a viable hybrid retrofit are much more significant than this BEV example however, according to Berthold.
“ When I look at how things have developed over, say, the last five years, there are two obvious factors that are strengthening the hybridisation business case,” he said.“ One, the supply chain has matured, meaning the cost for the components needed to carry out a hybrid retrofit have come down. Two, our own understanding of the types of projects – and the optimal timing for carrying them out – has developed to the point where the business case now looks a lot more compelling.”
On top of this, ABB has been able to carry out a significant amount of safety baseline work when it comes to these electric and hybrid solutions, starting at a battery cell level and moving up to bigger components and systems involved. opportunity to solve obsolescence and reliability issues as well as add the battery and other supporting power electronics,” he said.“ The mine owner can compare this opportunity with a standard rebuild offered by OEMs, as well as fleet replacement as part of the business case.
“ We are now seeing the hybrid retrofit become that much more competitive with these options.”
Hybridisation brings major fuel savings, boosts vehicle performance and reduces maintenance tasks for the diesel engine by lowering its load factor, according to ABB. Besides, it also helps to extend the asset life. Together, those benefits ensure a fast return on investment, typically ranging between two and four years, according to ABB.
Hybridisation also provides valuable field experience with battery systems to mine operators, easing the transition to full electrification later. This is very much in keeping with the interim steps mining companies are taking on their way to achieving net zero operations objectives.
Berthold said:“ Retrofitting and hybridisation enable operators to act now, enhancing fleet performance and productivity, reducing emissions and gaining valuable experience with electric systems, without requiring major infrastructure changes. For many, it’ s the easiest and most efficient way to bridge the gap between today’ s diesel reality and the fully-electric future.”
Practical and scalable decarbonisation
Earlier this year, Lundin Mining’ s majorityowned Caserones operation in Chile became the first active mine site in the world to operate an ultra-class haul truck with a hybrid-electric system.
The First Mode retrofit kit, delivered by Cummins, has been fitted on a Komatsu 930E truck( number 330) at Caserones.
Cummins has previously stated that the First Mode retrofit kit delivers immediate fuel savings and reduces emissions by up to 25 % with minimal changes to an existing ultraclass electric drive haul truck and requires no additional infrastructure. It cited extensive pilot opportunities last year, adding that scaled production could start in 2027 and beyond.
Caserones stated on the latest news:“ The pilot allows for an immediate reduction in diesel consumption, and it is estimated that savings can reach up to 30 % on average. Direct emissions, one of the main sources of mining’ s carbon footprint, are also immediately reduced.”
The pilot marks Cummins’ first deployment of a retrofitted 300-ton( 291 t) Komatsu mining haul truck into daily operation using a retrofit hybrid solution powered by its First Mode technology, Cummins added in a press release.
Designed as a retrofit kit for existing ultra-class mining haul truck fleets, the Cummins First Mode hybrid system integrates a Cummins QSK60 diesel engine with a modular, interchangeable high power electric battery system. Regenerative braking captures energy generated during loaded downhill hauls and stores it onboard, while intelligent control software seamlessly manages power flow between the engine and battery to optimise efficiency, reliability and performance across the full duty cycle of the truck.
Operating under real haulage conditions at elevations exceeding 4,000 m, the hybrid electric system demonstrates that hybridisation can deliver measurable efficiency improvements without disrupting production, Cummins says. At Caserones, the extreme conditions of the Andes and steep haul profiles provide an ideal proving ground for regenerative energy capture and reliable performance in a demanding mining environment.
Molly Puga, General Manager of First Mode, said:“ As Cummins marks the oneyear anniversary of acquiring First Mode, this milestone is the result of close collaboration between Cummins, Komatsu and Lundin
International Mining | APRIL 2025