Battery-powered mining machines could transform underground operations

The mining industry is undergoing a major transition as diesel-powered equipment is gradually replaced by battery-electric alternatives. Researchers at Luleå University of Technology have investigated how this shift affects everything from working conditions and ventilation requirements to productivity and operational planning. The results show that battery technology offers significant opportunities, while also introducing new challenges.

“Battery-electric machines affect much more than production itself. They also change how underground mines need to be planned and operated,” says Jenni Hooli, who recently defended her dissertation in Mining and Rock Engineering at Luleå University of Technology.

Moving away from diesel

The thesis Battery load-haul-dump (LHD) machines in underground mines examines the use of battery-electric LHDs in underground mining. Traditionally, these machines have relied on diesel engines that generate exhaust gases, diesel particulate matter and heat. Battery-powered machines eliminate these emissions at the point of use and can therefore change the conditions for underground mining.

“One of the biggest differences is that battery-electric machines do not generate exhaust emissions during operation, which affects the entire underground environment,” she says.

Cleaner air and lower ventilation requirements

Ventilation is one of the largest energy consumers in underground mines. Through field measurements in one operational area at LKAB’s Malmberget mine, the research investigated how ventilation requirements change when battery-electric machines replace diesel-powered equipment.

The preliminary results show that ventilation requirements can be reduced in the studied area, which in turn lowers ventilation energy consumption. Since ventilation often accounts for a substantial share of mine’s total energy use, even moderate reductions can have a significant impact.

“When heat and exhaust emissions decrease, the requirements for ventilation and cooling also change under normal operational conditions; however, these are preliminary results from one operational area and in order to generalise these results more studies are needed,” she says.

New operational challenges

At the same time, battery-electric operation introduces new logistical challenges. Machines need to be recharged or have batteries swapped, which affects production planning.

Using discrete even simulation (DES), the research analyzed how many batteries are required and how the number of batteries and machines influence productivity and queueing. The results show that careful planning is essential to avoid bottlenecks and delays.

“Battery swapping becomes a new part of the production system that has to function just as smoothly as the rest of the operation,” she says.

More than a technological shift

The study also explores how mine workers and management view the transition. Improved working conditions and lower emissions are seen as important benefits, while questions remain regarding costs, reliability and implementation.

“The technology is developing rapidly, but successful implementation requires understanding how it affects people, work processes and the mining system as a whole,” says Jenni Hooli.