Fleet Electrification in Mining: Case Studies Using 105 Ton Electric Dump Trucks

Introduction: The Drive Toward Electrification in Mining

The mining industry is at a critical crossroads. Pressured by environmental regulations, increasing fuel costs, and the global demand for carbon reduction, companies are rethinking how they power their operations. One of the most transformative shifts is the electrification of mining fleets, especially the replacement of diesel-powered haul trucks with large-capacity electric dump trucks.

Among the electrification solutions gaining rapid adoption are 105 ton electric dump trucks—a category that offers a powerful blend of hauling capacity, operational efficiency, and sustainability. This article explores real-world case studies showcasing the impact of these trucks in large-scale mining operations, and how their adoption is reshaping mine economics, logistics, and environmental strategy.

Why Electrify Haul Truck Fleets?

Key Benefits of Electric Mining Trucks

• Lower Operating Costs: Electric motors are far more efficient than diesel engines, with significantly lower fuel and maintenance costs.

• Zero Emissions at Source: Reduces on-site greenhouse gas (GHG) emissions and supports environmental compliance.

• Regenerative Braking: Captures energy during downhill runs, improving efficiency.

• Reduced Noise and Heat: Improves safety and worker comfort, especially in underground or high-temperature environments.

• Grid Integration and Renewable Synergy: Electric trucks can be powered by solar or wind energy in off-grid mining camps.

  
  

Case Study 1: Open-Pit Copper Mine, South America

Background

A major copper mine in Chile faced regulatory pressure to reduce its annual emissions by 30% by 2026. The site operated a fleet of 45 diesel trucks, each consuming an average of 250,000 liters of fuel per year.

Implementation

In 2023, the company introduced six 105 ton electric dump trucks in a pilot project, supplied with fast-charging infrastructure and solar integration for daytime operations.

Outcomes

• Fuel savings: ~$1.2 million per truck per year

• CO₂ emissions reduction: 300 tons per truck annually

• Downtime reduction: 22% improvement due to fewer mechanical breakdowns

• Noise pollution: Decreased by over 60% across critical haulage routes

Operator Feedback

Truck operators noted smoother rides, higher torque for inclines, and lower fatigue during long shifts—thanks to automatic controls and the absence of gear shifting.

Case Study 2: Iron Ore Mine in Western Australia

Background

This iron ore operation runs 24/7 across a 75 km² open-pit area. Haul roads are long and steep, making it a challenging environment for electrification.

Pilot Scope

Four 105 ton electric mining dump trucks were deployed with a focus on regenerative braking on long downhill routes. Charging was powered using a hybrid solar-diesel microgrid.

Results After 12 Months

• Operational cost per ton: Decreased by 18%

• Regenerative braking efficiency: Recovered up to 22% of energy

• Brake system maintenance: Cut by 50% due to less wear

• Battery cycle performance: 93% retention after 12 months (~1,400 charge cycles)

Strategic Insight

This site proved that even remote, rugged environments can benefit from heavy-duty electric dump trucks, provided that smart energy planning is in place.

Case Study 3: Lithium Mine in Inner Mongolia, China

Context

Lithium, a core material for battery manufacturing, is under increasing scrutiny for how it's mined. This lithium mining operator aimed to make its supply chain cleaner and more appealing to downstream EV and battery manufacturers.

Strategy

The company partnered with a local OEM to trial ten 105 ton electric dump trucks, designed with modular lithium iron phosphate (LFP) battery packs and AI-based predictive maintenance.

Key Metrics

• GHG certification: Achieved “Low-Carbon Mining Certification” from a regional energy agency

• Battery swap time: Reduced to under 12 minutes via robotic arms

• Monthly fuel savings: Over $800,000 across the 10-truck fleet

• Customer impact: Two major battery makers signed preferential contracts after ESG score improvements

  
  

  
  

Barriers to Adoption

Despite the success stories, electrifying mining fleets using heavy-duty electric dump trucks comes with challenges:

• Upfront investment: The purchase cost of an electric truck can be 30–50% higher than its diesel equivalent.

• Charging infrastructure: Requires robust planning, especially for remote or off-grid locations.

• Battery degradation in cold climates: Performance can drop if thermal management is insufficient.

• Load variability: Certain haul profiles may not fully exploit the benefits of regenerative braking.

  
  

  
  

The Technology Behind 105 Ton Electric Dump Trucks

Core Features

• Battery capacity: Typically ranges from 700 kWh to 1 MWh

• Motor output: ~1,200 kW peak power

• Chassis: Reinforced for mine-grade durability

• Smart telemetry: Real-time diagnostics, energy usage, and predictive maintenance alerts

• Battery swapping or fast-charging: Depending on mine layout and operational cadence

These machines are designed to perform in harsh conditions—whether arid deserts, high-altitude mines, or icy terrains—with battery heating/cooling systems and IP67-rated electronics.

Environmental Impact Assessment

The transition from diesel to electric in mining fleets—especially with trucks in the 100+ ton range—has significant environmental implications:

• Annual emissions reduction per truck: Up to 300–500 tons CO₂e

• Noise reduction: Up to 70% lower than diesel counterparts

• Particulate matter elimination: Reduces worker exposure to harmful diesel exhaust

• Supports ESG reporting: Electric fleets align with Scope 1 & 2 emission targets under GRI/SASB frameworks

  
  

  
  

ROI Considerations for Mining Operators

Payback Period

With fuel savings and reduced maintenance, most mining operators report a return on investment within 3 to 4 years for electric dump trucks.

TCO (Total Cost of Ownership)

Over a 10-year lifespan, electric trucks often show 25–35% lower total cost of ownership compared to diesel trucks—even when accounting for battery replacement in years 5–7.

Financing and Incentives

In some countries, tax credits, carbon trading, or green finance instruments are available to subsidize part of the transition cost.

Future Outlook: What's Next for Electrified Mining Fleets?

• Autonomous Electric Trucks: Combining autonomy with electrification for maximum operational efficiency.

• Hydrogen-Electric Hybrids: Being explored for ultra-long-distance hauling.

• Battery-as-a-Service (BaaS): OEMs offering battery replacement programs and usage-based pricing.

• Fleet-wide AI Optimization: Using machine learning to schedule charging, reduce idle time, and extend battery life.

As battery technologies evolve and power generation becomes cleaner, the case for large-scale electrification becomes even more compelling.

Final Thoughts

The adoption of 105 ton electric dump trucks in mining is more than a technological trend—it's a strategic move toward resilient, cost-efficient, and environmentally responsible operations. These case studies offer tangible evidence that electrification is not only possible in large-scale mining but also profitable and sustainable.

Ready to Electrify Your Mining Fleet?

Leverage the proven performance of 105 ton electric dump trucks backed by real-world data. Whether you're operating in copper, iron ore, lithium, or coal—learn how leading mines are transitioning their fleets with technology that works.

Looking to future-proof your haulage operations? Discover the KNOW-HOW that leading mining companies already trust.