December 3, 2024 – Hitachi Construction Machinery Co. Ltd. commenced the technological feasibility trial of the world’s first* ultra-large, full battery rigid-frame dump truck by an OEM, which it developed alongside its electrification partner ABB.

“Mining companies around the world are working to reduce emissions,” said Hitachi Construction Machinery’s Eiji Fukunishi. “The battery dump truck represents the future, not only for the Hitachi Construction Machinery Group but for the mining industry as a whole […]”

The dump truck is being put through its paces at First Quantum Minerals Ltd.’s Kansanshi deep open-pit copper and gold mine in the Republic of Zambia.

The feasibility trial aims to verify the dump truck’s basic performance (e.g. travelling, turning, stopping) under actual operating loads, as well as battery performance.

The Kansanshi mine provides Hitachi with the infrastructure and facilities that are needed to test a full-battery dump truck, says the OEM, including overhead dynamic charging solutions and a variety of haul circuits in an actual operational mining environment.

In the beginning …

Hitachi Construction Machinery began collaborating with ABB’s Traction division in June 2021 to create the fully electric dump truck for heavy-duty mining operations.

Conceptual image of completed full battery rigid dump truck.

Utilizing ABB’s battery technology and DC/DC converters, Hitachi trucks can be transformed from diesel to fully electric operation. The dump trucks use a new onboard electric system that draws energy from the trolley supply to directly power the motor while charging the battery energy storage system.

In operation on level ground, the dump truck will run on its internal battery. While travelling uphill, it will draw power from the external trolley supply.

When running downhill, the regenerative braking system charges the battery, which reduces the charging load when the truck is connected to the trolley. This enables the truck to stay in continuous operation with no breaks for charging, thereby maintaining productivity.

In addition, limiting the battery volume reduces the battery weight as a percentage of the overall vehicle weight, helping to maximize the dump truck’s load capacity.

Full battery rigid dump truck under testing.

After undergoing in-factory testing, the prototype was shipped in January 2024 to the Kansanshi site.

“The project is not only helping to tackle the issues involved in dump truck electrification, but is also contributing to enabling a low-carbon world through the reduction of greenhouse gas emissions,” said ABB Traction’s Fabiana Cavalcante. “We look forward to seeing the prototype prove its capability in the Zambian copper-gold mine.”

Global recognition

Last month, the ultra-large full battery dump truck won Silver in the 2024 Anthem Awards, under the Responsible Technology category.

An initiative of The Webby Awards, the Anthem Awards honours “the purpose and mission-driven work of people, companies, and organizations making a difference worldwide”.

* As of June 27, 2024, based on a survey conducted by Hitachi Construction Machinery of ultra-large dump trucks with a load capacity of 150 tons or more manufactured by OEMs.

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