Rolls-Royce Power Systems is set to begin field testing of a new hybrid drive system for haul trucks in autumn 2026, aimed at enhancing fuel efficiency and reducing emissions in mining operations.
The system integrates mtu Series 4000 engines with an electric drivetrain.
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Based on the mine’s terrain and operational characteristics, it can reduce fuel consumption and CO₂ emissions by as much as 30% compared to traditional drive systems.
The hybrid system captures the haul truck’s braking energy in batteries during downhill travel.
This energy powers the wheel motors on the uphill ascent, reducing the load on the diesel engine and lowering fuel consumption significantly.
The goal is to create a modular, scalable system adaptable to various vehicle types, mine terrains and operational conditions.
As demand for critical minerals grows for the energy transition, electromobility and data centre needs, mining companies are committing to a 30–40% reduction in CO₂ emissions by 2030 and aiming for climate neutrality by 2050.
Rolls-Royce Power Systems global mining vice-president Cobus van Schalkwyk said: “With this new development, Rolls-Royce is responding to a growing drive from the global mining industry to operate more efficiently and sustainably.”
For years, mtu diesel engines have reliably powered a range of open-pit mining equipment, from drilling rigs and excavators to wheel loaders and haul trucks, regardless of whether they use diesel-mechanical, diesel-electric or diesel-hydraulic systems.
The mtu Series 4000 engines are designed for versatile and continuous use, and key variants are compatible with hydrogenated vegetable oil, which considerably reduces their carbon footprint.
Schalkwyk said: “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.”
