As pressure mounts on the mining industry to reduce emissions, researchers are examining whether hydrogen fuel cell haul trucks can realistically replace diesel-powered fleets - promising cleaner operations while raising new questions about cost, safety, and on-site feasibility.
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In a recent review published in Mining, Metallurgy & Exploration, researchers examined the integration of hydrogen fuel cell technology into mining haul trucks and its potential implications for decarbonization and long-term sustainability within the mining sector.
Why Mining is Looking Beyond Diesel
The mining industry has long depended on diesel-powered haul trucks, which contribute substantially to greenhouse gas (GHG) emissions. As regulatory and societal expectations rise, the need for cleaner, more efficient alternatives becomes increasingly urgent.
Hydrogen fuel cells have entered this conversation as a potential option - one that could offer diesel-like performance without compromising safety, practicality, or operational efficiency.
This growing interest is driven by concerns over emissions, as well as the mining sector’s broader environmental, social, and governance (ESG) commitments. The review positions hydrogen fuel cells as a possible step toward meeting these commitments while supporting ongoing productivity demands.
Key Studies Evaluated in the Review
The review brings together several technical studies assessing the feasibility of using hydrogen fuel cells in large mining vehicles.
Simulation-based performance insights
A central study used a detailed MATLAB/Simulink model based on real data from a Komatsu 830E-5 haul truck. This simulation allowed researchers to test energy use, fuel needs and operational constraints under realistic mining conditions.
The results were encouraging: a hydrogen fuel cell system could meet similar drive cycles to diesel-powered trucks. However, the analysis also underscored meaningful challenges. Storing enough hydrogen onboard is difficult due to the volume and pressure required, which may force designers to make room for larger tanks. This could reduce payload capacity or affect driver comfort. Integrating fuel cell stacks, power electronics, and batteries only adds to the space and weight considerations.
Economic, logistical, and safety considerations
Other studies highlighted in the review focused on the broader ecosystem challenges:
- Cost Barriers: Hydrogen remains costly - often two to three times more expensive than hydrogen produced from natural gas.
- Infrastructure Hurdles: Remote mines lack suitable pipeline infrastructure, making hydrogen delivery complex and expensive.
- Safety Concerns: Hydrogen’s flammability and required high-pressure storage call for strict safety protocols, especially in environments where explosives are already present. The review notes that risks such as accidental ignition or deliberate sabotage must be addressed with robust systems and planning.
Where Current Research Falls Short
A recurring theme in the review is the lack of real-world data. Most existing studies rely heavily on models or conceptual frameworks. As a result, researchers recommend expanding simulations to include:
- Terrain variability
- Changing power demands
- Environmental conditions such as extreme temperatures
- Component aging and long-term degradation
These refinements could help predict the durability and reliability of hydrogen fuel cell systems before large-scale adoption.
Operational Implications for Mining Companies
Transitioning to hydrogen fuel cell trucks would require significant adjustments to current operations, including supply chains, maintenance procedures, and safety protocols. Despite these challenges, hydrogen systems offer meaningful benefits:
- Zero tailpipe emissions
- Potential for performance on par with diesel engines
- Alignment with climate targets and ESG priorities
Still, achieving comparable driving ranges remains a challenge due to storage constraints. Mines may need larger tanks or more frequent refueling cycles - both of which affect productivity and truck design.
Final Takeaway
The review concludes that hydrogen fuel cell trucks represent a promising route for reducing emissions in mining, particularly given the heavy-duty performance demands of haul trucks.
While technical studies indicate that these systems could match diesel performance, several hurdles - cost, infrastructure, safety, storage capacity, and limited real-world data - must be addressed before widespread adoption becomes realistic.
Hydrogen fuel cell technology may not be ready for full-scale deployment today, but it offers a clear direction for future exploration as the mining sector works toward more sustainable haulage systems and broader decarbonization goals.
Journal Reference
Akinrinlola A., Awuah-Offei K., et al. (2025). Evaluating feasibility of incorporating fuel cell drive trains into existing haul trucks. Mining, Metallurgy & Exploration. DOI: 10.1007/s42461-025-01361-7, https://link.springer.com/article/10.1007/s42461-025-01361-7