Decarbonization: Movement and Energy
How OEMs, Material Handling and Power Management firms are slashing emissions
The challenges to achieving decarbonization road maps in the mining industry need to be tailored by operation, addressing the key pillars of decarbonization: energy efficiency, hybrid power, microgrid integration, alternative vehicles, mine design, and process adaptation to alternative energy sources. OEMs, equipment component manufacturers, power management and material handling firms are working diligently to find ways to reduce emissions.
De-fleeting carbon footprints
The mining fleet is one of the primary sources of on-site GHG emissions. For surface mines, mobile mining equipment can account for up to 30% of GHG emissions. This rises to 80% for mines lacking onsite smelting or refinery facilities. Large mining trucks alone represent more than 50% of a surface fleet’s emissions. Electrifying a single truck reduces emissions to save 3,000 m2/y of artic ice, eliminates the same amount of CO2 it takes 46,000 trees to absorb, and lowers oceans CO2 absorption by 1,000 t/y, according to research by ABB.
“While electrification is on the horizon, the transition in the US is likely to be slower compared to other markets due to concerns about battery life, infrastructure investments, and the need for companies to evaluate the best return on decarbonization strategies. Some companies may prioritize other technologies, like automating existing fleets to achieve carbon footprint reductions,” said Jon Torpy, general manager and president at Epiroc.
Decarbonization through automation does seem to be the priority, as exemplified by Arizona-based Freeport-McMoRan. In 2023, the miner approved a new project to convert the fleet of 33 haul trucks at the Bagdad operation in Arizona to become fully autonomous by 2028. Emissions from haul trucks are projected to decline due to reductions in idle time and increased efficiency. Idle time is estimated to decrease by 10,000 hours, according to the firm’s Climate Report. Full autonomy is also an important step to electrification, explained Joshua Olmsted, president and COO, Freeport-McMoRan Americas, “As haulage electrification progresses over the next 5 to 10 years, managing an electric fleet will introduce complexities like charging schedules and logistics. Autonomous systems will streamline this transition, making electric haulage more feasible and efficient.”
Automation will play a major role no matter the energy source, echoed Diederik Lugtigheid, general manager of surface mining automation – haulage at Epiroc: “Automation will be key in managing battery, trolley, or hydrogen-powered trucks, ensuring their connection to power grids and energy systems is seamless. Automation and electrification need to work together to help the industry meet sustainability goals.”
In the US, hybrid solutions provide an emission reducing alternative, said Torpy: “Hybrid solutions, such as our Boltec M SG Battery bolter and MT66 S eDrive hybrid truck, are expected to be more popular in the US than fully electric options.”
Fleet emissions can be reduced without investing in new equipment. Tire manufacturing firms Michelin and Bridgestone are aiding this effort. “We introduced the Michelin XDR 4 SPEED ENERGY, designed to improve fuel efficiency by 3.6% compared to the Michelin XDR 250 C tire, savings about 5,300 gallons/y of fuel and reducing CO2 emissions by 2,600 t/y for a fleet of 50 trucks,” said Adam Murphy, senior vice president, Michelin Global Mining.
With their new Smart On-site initiative, Bridgestone increases resource productivity, lowering emissions and reducing downtime. Utilizing data and predictive AI-based algorithms, Bridgestone “supports customers in potentially reducing the number of trucks needed for operations and increasing haul cycles, which leads to a more efficient operation overall”, said Rob Seibert, president, Bridgestone Americas.
Trucks, or course, are not the only material handling method, and, given shifts in the Western US mining sphere, they are not the most efficient solution either. Steffen Gjorvad, president of Takraf USA, elaborated: “Emissions from trucks are significantly reduced by using conveying systems, and the logistics of moving trucks in tunnels is complicated. We see more applications using conveyors due to their efficiency, requirement for higher volumes due to decreasing ore grades and the trend to move from open-pit mines to underground operations.”
Energy: Decarbonization’s capital
Decarbonization is expensive; the combined capital expenditure of the top 19 mining companies is expected to reach US$71.0 billion in 2024, rising 10.6% compared with 2023, with many citing decarbonization as a leading cause of increase. BHP, for one, will allocate US$4 billion towards decarbonization efforts by 2030. Energy has become the industry’s most significant form of capital; “Energy costs comprise 15-30% of a mining company's expenses, with a significant portion of that being electricity. Producing a ton of copper ore requires 30-100 kilowatt-hours of energy, depending on the mine”, said Willem Van Twembeke, CEO of Inkia Energy.
Traditional conveying systems can account for 80% of a mine’s energy consumption, increasing Scope 3 emissions. Takraf utilized innovation through partnership with ABB to introduce gearless drive technology, which reduces energy consumption 6-10% and reduces direct emissions: “A study showed that CO2 emissions compared to diesel truck engines for the same copper production volume were reduced by 66% when using gearless drive technology,” highlighted Gjorvad.
At Freeport-McMoRan’s Chino mine, Bosch Rexroth replaced aging gearboxes and electric motors with advanced drive systems. Ashok Amin, segment manager Americas of bulk material handling, explained the benefits: “Replacing a single 1,500 HP drive with a modular system of three 300 HP motors enables us to shut off motors during lower demand periods, resulting in substantial energy savings. This modular approach enhances operational efficiency and newer technologies are specifically designed to reduce energy consumption.”
As energy costs climb and mining operations increasingly require deeper resource extraction, optimizing electrical efficiency is essential. Peter Rowland, Canada solution sales manager at Yokogawa, echoed the sentiment: “It is all about efficiency and optimization now, whether in production, safety or environmental aspects.”
Microgrid utilization is increasing in the industry as a steppingstone for resilient, cleaner operations. Marc Elliott, marketing director of mining, metals and minerals at Eaton elaborated: “Our microgrid solutions enable customers to minimize reliance on carbon-intensive energy sources. By facilitating the transition to cleaner energy options and improving overall energy management, we help clients become more resilient and less dependent on fossil fuels.”
“Although new copper and gold mines are limited, robust demand drives companies to invest in modernization and efficiency enhancements.”
Ashok Amin, Segment Manager, Americas, Bulk Material Handling, Bosch Rexroth
Digital decarbonization
When it comes to energy efficiency, digitalization allows for better management of energy consumption, and asset efficiency. Yokogawa’s Collaborative Information Server allows operations to remotely monitor data from a mining operation, allowing companies to identify leaks and optimize energy usage, said Greg Heiges, mining business development manager: “By integrating the handling of all kinds of data from plant equipment, devices and systems, this solution facilitates the optimized management of production activities across an entire enterprise.”
Eaton’s solution is the Brightlayer Industrial suite. “This offers intelligent software solutions that integrate into existing systems, enabling real-time monitoring and control of energy usage”, said Elliot.
Net zero is a paradigm shift that requires collaboration among all industry players: “The transition to sustainable energy and addressing climate change are global issues far beyond any single company's balance sheet. To tackle these challenges effectively we will need a higher level of partnership between mining companies and external agencies over the next 20 to 30 years than we have seen in the past century”, emphasized Nathan Foster, managing director Kennecott at Rio Tinto.
Collaborative efforts have brought dramatic change. Takraf partnered with ABB. Eriez created a consortium with the University of Queensland including industry leaders like Rio Tinto, Newmont, Newcrest, Anglo American and Oz Minerals to develop CPF technology. Decarbonization in the mining industry will be a global effort, as we all share one planet. The industry is making headway, only time will tell if it will be enough.
Article header image courtesy of Michelin