Mining has long relied on powerful, heavy-duty equipment to extract raw materials from the earth. However, battery-electric vehicles (BEVs) are making a noticeable impact across the industry. These machines restructure how mines operate, with significant implications for sustainability, efficiency, and overall costs. This article explores how BEVs are currently used in mining, highlights recent research, and looks at the challenges and opportunities of adopting battery-electric equipment.
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The Global Shift Toward Battery-Electric Mining Equipment
Mining companies are gradually adopting BEVs to replace diesel-powered machinery in surface and underground operations. Emission reductions, regulatory compliance, and cost considerations are all reasons for this shift.
Global Mining Review recently conducted a market analysis and found that electrification is becoming a key component of decarbonization strategies in mining, with 91% of surveyed companies considering it essential for sustainability plans.1
Industry projections suggest steady growth for battery-electric mining vehicles, with an anticipated compounded annual growth rate (CAGR) of up to 32% for electric haul trucks, loaders, and light vehicles by 2044.2,3
Environmental Benefits of BEVs
Unlike diesel engines, BEVs produce zero on-site greenhouse gas emissions or tailpipe pollutants. A recent industry review suggests that electrified mining equipment can reduce operational emissions by up to 50% compared to diesel-powered machinery.4,5
Lower particulate emissions improve air quality in mines, support miner health, and lower energy requirements for ventilation.4,6
Economic Impact and Cost Efficiency of BEVs
Electric mining equipment offers substantial cost savings over its operational lifespan.2,4
Electric motors have fewer moving parts, reducing maintenance requirements and downtime. Fuel expenses also decrease as EVs run on more stable electricity instead of volatile diesel markets.3,5
Although the initial capital investment for BEVs is often higher than diesel-powered counterparts, lower operating costs can offset this over time. Some studies suggest that future reductions in battery prices and advancements in charging technology may further improve cost-effectiveness.4,7
The 2024 Electric Vehicles in Mining report highlights advancements in battery size, chemistry, and charging regimes that support longer run times and less frequent battery replacements.3
BEVs also perform well at high altitudes, where diesel engines typically underperform due to thinner air. As battery density improves, the machinery's range and power will increase, allowing electric units to handle many tasks reliably.5,8
Is Electric Mining Equipment Safer?
Electric motors operate more quietly and generate less heat than their diesel equivalents. This reduces workers' exposure to harmful noise and thermal stress, leading to a safer and more comfortable working environment. BEVs also eliminate diesel fumes and reduce airborne dust, resulting in fewer respiratory hazards for miners.
Improved workplace safety and health outcomes helps mining companies recruit and retain talent and reduce workers’ compensation and health costs.4,5,6
However, battery swapping and charging introduce safety concerns. Researchers emphasize the need for robust protocols for battery handling, charging, and maintenance to avoid electrical hazards and ensure batteries do not fail under harsh mining conditions.
Studies conducted among mine personnel provide useful insights into risk perceptions and the effectiveness of new safety measures implemented alongside BEV adoption.6,9,10
Based on the studies, adopting battery electric vehicles (BEVs) in underground mining introduces benefits and safety challenges as perceived by mine personnel.
Overall, workers value BEVs for reducing noise and eliminating diesel particulate emissions, leading to a quieter and cleaner underground environment. However, significant concerns persist around fire safety due to the risks posed by high-energy batteries, especially in the event of collisions or improper handling, as well as limitations related to battery runtime and charging logistics.
Mine workers identified knowledge gaps in effective emergency response, battery identification, and suppression methods, highlighting the need for targeted safety training, clear protocols, and improved communication around the new risks unique to BEVs compared to conventional diesel equipment.
Interviews, surveys, and organizational reviews revealed that risk perception among mine personnel is shaped by previous experience, education, and the overall safety culture within the organization. Effective BEV implementation is closely tied to worker involvement in safety planning, robust training programs tailored to various roles, and proactive engagement strategies to support trust and encourage open communication about new risks.
Successful safety measures depended as much on technological readiness as on prepared and informed personnel, with studies showing that developing a positive safety culture, frequent risk communication, and demonstrable organizational support are crucial for building risk awareness and compliance with new procedures.
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While BEVs are welcomed for their environmental and health advantages, ongoing investment in adaptive safety frameworks and continuous professional development for mine staff remains essential to address evolving risk profiles and protect worker wellbeing.
Battery-Electric Mining Developments
Significant progress has been made in recent years in the development of batteries designed specifically for heavy-duty mining applications.
A recent advancement is a high-energy density lithium-ion battery pack that supports longer usage cycles and enhances safety features for mining vehicles and locomotives.8 Mining companies collaborate with battery manufacturers, equipment original equipment manufacturers (OEMs), and technology firms to promote pilot programs and advance research and development.2,11
The Oyu Tolgoi mine in Mongolia, operated by Rio Tinto, highlights these advances in practice. The mine has reported successful operational trials after integrating BEVs into its underground fleet, including haul trucks and loaders. Machines such as battery-electric bolters and 18-ton loaders now operate on-site, contributing to the electrification of mining activities.11
Operational and Infrastructure Challenges
Despite strong progress, several challenges hinder the widespread adoption of BEVs in mining. Key issues include battery longevity and durability, particularly because mines present harsh operational conditions.
Recent studies emphasize the need for batteries to maintain performance during intensive duty cycles. The initial capital costs associated with electric equipment and necessary infrastructure upgrades, such as charging networks and power storage, may discourage some operators from transitioning.4,7
Operational challenges also play a significant role. Efficient energy management and charging scheduling are essential to minimize downtime. The productivity of mining operations is closely linked to the availability of charging and battery-swapping facilities, highlighting the importance of advanced site planning and investment in power management systems.
Furthermore, upskilling mine operators and maintenance personnel on EV technology is crucial. Addressing these challenges will require collaborative efforts from companies, technology providers, and government entities through research, incentives, and training initiatives.4,6,7,9
Battery-Electric Vehicles Case Studies
Recent high-profile deployments of BEVs in mining provide tangible evidence of the sector’s progress.
The collaboration between Boliden, Epiroc, and ABB led to the introduction of a fully battery-electric trolley truck system at the Chuquicamata mine in Chile, which improved emissions and operational costs while setting a precedent for similar projects worldwide.
The Oyu Tolgoi project demonstrates how careful planning and integrating multiple BEV models can deliver desired safety and productivity outcomes.2,11
Industry data shows that many sites choose a phased transition, starting with ancillary vehicles before moving on to primary load-and-haul systems. The learnings from early pilots accelerate adoption and reduce risk as technologies mature and infrastructure needs become clearer.2,3,11
The Future of Mining Electrification
Switching mining equipment to electric power opens up new possibilities for safer, cleaner, and more efficient mining. Recent studies, industry feedback, and real-world examples show battery-electric machines can deliver real environmental, economic, and health benefits.
Due to larger batteries and faster charging, these electric machines can now handle various tough mining jobs. Plus, stricter regulations and public demand for more environmentally friendly mining encourage companies to invest in this technology.
Of course, some obstacles remain, such as high upfront costs, the need for new site infrastructure, and helping workers adapt to these changes. However, these challenges are being ironed out as the industry collaborates and develops new solutions.
With continuing improvements in battery and digital technologies, fully electric mining operations are becoming more realistic and attractive. Before long, we can expect to see more and more battery-powered vehicles in the mining sector.
References and Further Reading
- Watts, J. (2025). Mining's Moment To Go Fully Electric. Global Mining Review. https://www.globalminingreview.com/technology-digitalisation/16042025/minings-moment-to-go-fully-electric/
- Janberg, W. (2024). Revolutionizing Underground Mining: The Rise of Battery-Electric Equipment. Report Linker. https://www.reportlinker.com/article/6809
- Jaswani, P. (2024). Electric Vehicles in Mining 2024-2044: Technologies, Players, and Forecasts. IDTechEx. https://www.idtechex.com/en/research-report/evs-in-mining/994
- Electrification of Mining Equipment: Top 5 Benefits 2025. (2025). Farmonaut. https://farmonaut.com/mining/electrification-of-mining-equipment-top-5-benefits-2025
- Mining Industry: Transition to Electric Machinery. (2024). Leadvent Group. https://www.leadventgrp.com/blog/mining-industry-transition-to-electric-machinery
- Hooli, J., & Halim, A. (2025). Battery electric vehicles in underground mines: Insights from industry. Renewable and Sustainable Energy Reviews, 208, 115024. DOI:10.1016/j.rser.2024.115024. https://www.sciencedirect.com/science/article/pii/S1364032124007500
- Gleason, W. (2023). Battery-electric vehicles for mining; challenges and opportunities. Mining Engineering. https://me.smenet.org/battery-electric-vehicles-for-mining/
- Global Mining Electric Locomotive Battery Market 2024–2033. (2024). Custom Market Insights. https://www.custommarketinsights.com/report/mining-electric-locomotive-battery-market/
- Martinetti, A. et al. (2025). Safety Challenges in Battery Swapping Operations of Electric Underground Mining Trucks. Applied Sciences, 15(12), 6763. DOI:10.3390/app15126763. https://www.mdpi.com/2076-3417/15/12/6763
- Hooli, J., & Halim, A. (2025). Battery electric vehicles in underground mines: Insights from industry. Renewable and Sustainable Energy Reviews, 208, 115024. DOI:10.1016/j.rser.2024.115024. https://www.sciencedirect.com/science/article/pii/S1364032124007500
- Oyu Tolgoi battery-electric equipment developments intensify. (2025). International Mining. https://im-mining.com/2025/01/02/oyu-tolgoi-battery-electric-equipment-developments-intensify/
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