Recent advancements in electric vehicle (EV) and battery technology have made it feasible to electrify large-scale mining equipment including haul trucks. However, electrification remains at an early stage and faces a range of infrastructural, financial, technological and operational challenges. 

Power infrastructure requirements and the cost of technology are seen as the two main barriers to investment in battery-electric vehicles (BEVs) in the mining sector, according to a recent GlobalData survey.  

More than a quarter of the respondents to a survey run on Mining Technology in June/July pointed to power infrastructure requirements as the main barrier to investing in BEVs, with a similar proportion (24%) identifying the cost of technology as the principal obstacle.  

Other barriers to investment include regulatory uncertainty (18%), limited return on investment (17%), technology readiness (8.2%) and skills requirement (7.7%). 

Infrastructure needed to support mine electrification 

Power infrastructure requirements are seen as the main barrier to investment in electric mining vehicles, according to the GlobalData survey.  

The electrification of mining fleets requires robust infrastructure including charging stations, low-carbon generation capacity and energy storage systems. However, the remote locations of many mining operations complicate deployment.  

“Energy infrastructure is going to play an important role. Whether the mine is remote or connected to the grid, having clean and cost-effective energy available is key,” Ratna-Kanth Dittakavi, global eMine sales manager at ABB, tells Mining Technology.  

According to Alex Phillips, energy transition analyst at GlobalData, energy supply can be achieved through power-purchase agreements or installation of on-site renewables.  

“Regardless of the mine location, utility-scale energy storage will be key to ensuring a stable electricity supply for operations,” Phillips adds.   

“However, developing co-located energy storage capacity presents an additional cost barrier to transitioning to renewable electricity.” 

The cost of deploying BEVs in mining 

The substantial upfront capital cost required to purchase electric trucks and the associated battery technologies was flagged by around a quarter of survey respondents as the primary barrier to the adoption of BEVs in mining.  

In fact, research suggests that the upfront cost of battery-electric mining trucks can be twice as much as diesel-powered alternatives.  

This can deter companies from switching to electric equipment, especially given the early stage of the technology and uncertainties surrounding future operational performance.   

Efficient use of trucks is critical for mining operations, as Dittakavi explains: “If your trucks have to stand still to charge, you need more trucks to move the same amount of material, which increases the capex [capital expenditure].” 

Although there are potential operational cost savings from going electric – due to absence of fuel costs and lower maintenance overheads – 17% of those surveyed identify limited return on investment as a key barrier to the adoption of electric mining vehicles.  

Regulatory uncertainty 

Regulatory uncertainties also pose a significant challenge to the adoption of BEVs in the mining industry, with 18% of those surveyed citing it as their chief concern.  

“While the shift towards electric mobility is seen as a crucial step towards decarbonising the mining industry, the pace of adoption is constrained by a fragmented regulatory environment,” says Phillips.  

Different countries impose varying standards and incentives for BEV deployment, creating “a complex compliance landscape for miners”, he adds. In some regions (Europe, for example), stringent emissions regulations are driving the adoption of BEVs, while in others, such as the US, the lack of clear regulatory frameworks or incentives may delay investment.  

“This uncertainty increases risk for mining companies, particularly when considering the capital-intensive nature of fully electrifying fleets,” Phillips explains.  

“Furthermore, regulatory delays on charging infrastructure or battery safety standards such as battery disposal and recycling regulations add complexity to the transition and increase operational risks for mining companies.”  

Developing technologies 

Although many miners have committed to electrifying their equipment fleets, 8% of respondents believe technology readiness remains a major challenge.  

While advancements in battery technology are progressing, the current capacity of batteries is still limited. Mining trucks and charging infrastructure need to be redesigned to meet operational needs.  

Nevertheless, pilot projects are under way around the globe.  

Fortescue is recognised for its aggressive push towards electrification. As part of a $2.8bn (A$4.3bn) deal signed with Liebherr in September 2024, the company is working to develop one of the world’s largest zero-emission mining fleets, comprising 475 machines, for its operations in Western Australia. 

Both BHP and Rio Tinto are also actively trialling battery-electric haul trucks in their Pilbara iron ore operations, collaborating with Caterpillar and Komatsu. 

Vale has introduced battery-powered trucks into its operations in Brazil and Indonesia, marking a significant step in its electrification journey. In 2024, the Brazil-based miner revealed plans to test additional battery-electric trucks at Minas Gerais in collaboration with Caterpillar. The companies are also exploring dual fuel solutions for haul trucks running on ethanol and diesel. 

Hitachi Construction Machinery and ABB are collaborating to develop a full battery-electric rigid dump truck for mining operations, with a prototype undergoing testing at First Quantum Minerals’ Kansanshi copper-gold mine in Zambia. The truck uses existing trolley lines at Kansanshi to charge while in motion, with no impact on productivity. 

In China, Eacon Mining has supported deployment of 29 Yutong EY70E battery-electric mining trucks in the Pingyin and Shuichang quarries, as well as three battery-powered XCMG EX80 models at Zijin’s Zijinshan copper-gold mine.  

The quest for standardisation  

With this range of original equipment manufacturers (OEMs) and technology providers, a lack of standardisation may complicate the adoption of BEVs at mine sites. 

“The challenge mining companies are facing is they do not want to lock in with a single OEM truck, but different OEMs have different electrical specifications. For example, some of the trucks work on 1,800 volts (v) DC [direct current] while some work on 2,600v DC,” says Dittakavi. 

“How would a customer install an infrastructure that could run both of these trucks with different voltage levels?” he asks.  

Dittakavi believes that collaboration across industry – among OEMs, miners, technology providers, industry regulatory bodies, mechanical retrofitters and others – is key to achieving interoperability standards and, eventually, electrification and energy transition goals. This sentiment is echoed in ABB’s Mining’s Moment report, in which 71% of mining companies agreed that successful partnerships are key to gaining momentum in the energy transition. 

Through various collaborations, ABB has been working to develop technology-agnostic solutions based on “open standards and open communication protocols”, Dittakavi notes. In August 2024, the company signed a strategic agreement with Komatsu to co-develop electrification and decarbonisation solutions for the mining industry. It also has a memorandum of understanding with Epiroc to advance collaboration on underground trolley solutions for the mining industry and an agreement with Sumitomo Corporation to develop strategies for decarbonising mining equipment. 

The outlook for BEVs in mining 

The penetration of BEVs in the mining industry is growing, with Epiroc reporting that total utilisation more than doubled during 2024. This reflects the start of a shift from trial operation to full-scale production use, but it is likely to take until the end of this decade before there is widespread deployment.  

As of March 2025, GlobaData was tracking 271 trolley-assist trucks operating on surface mines and 387 battery-powered surface trucks across the globe. There were a further 293 electric loaders and 89 electric trucks operating in underground mines.  

“Miners are showing increasing signs of adopting EVs driven by environmental goals, improved operational efficiency and long-term cost savings,” says Phillips.  

“However, the level of investment needed to develop complete electric ecosystems within mines makes full fleet electrification unfeasible in the near term, with commercial viability expected between 2035 and 2040.”  

Other challenges, such as battery limitations for heavy-duty vehicles, increased power demands, the lack of utility-scale fast-charging infrastructure and regulatory uncertainties, remain significant obstacles.  

Nevertheless, Philipps suggests: “With the development of comprehensive regulatory frameworks, enhanced policy incentives, increased investments in infrastructure and continuous technological innovation, the transition to full-fleet electrification can be accelerated.”