Electric mining vehicle pilot project

The project, launched on February 19, 2020, aims to validate the viability of heavy electric trucks for use in open-pit mining. A consortium of partners has collaborated in the electrification of a Western Star 6900 XD truck specifically adapted to mining needs. A dedicated charger was developed to charge the vehicle, and an electric drive system was designed to meet requirements specific to mining operations.

The design phase took until September 2020 and included simulations and tests to optimize the vehicle’s dimensions. After it had been approved, it took until September 2021 to draft a detailed design, and the vehicle was assembled in December 2022. Tests were conducted on the truck between January 2023 and March 2024. These were run intermittently so that it could be tested in different weather conditions.

Three testing periods:

The electric vehicle testing project produced varied results across three distinct trajectories. Tests revealed very interesting performance results, specifically in terms of operating range and energy consumption, with significant variations depending on the route conditions.

Feedback from the drivers highlighted that performance was comparable, if not superior, to that of diesel vehicles, despite a few technical problems with the batteries, as the truck was a prototype. The vehicle’s activation delays and the necessity for rapid charging were also highlighted as points needing improvement.

A report by IVI indicated the electric vehicle’s potential in an operating environment, while also identifying ways to optimize range, charging and reliability. Based on the results, switching to an electric vehicle could result in significant long-term economic and environmental advantages, despite the issues encountered.

After the end of the project, the electric mining vehicle was returned to the NMG mine site. It will be used mostly as a demonstration model and might be used for light work. Everything is currently running well, and there are plans to train the respective employees in December 2024. NMG used the electric truck for demos and plans to use it for a small construction project this fall. The truck will be used to haul rocks, stumps and earth on the mine site.

Meanwhile, other stakeholders, such as Propulsion Québec, Institut du véhicule innovant (IVI) and the NRC are working on sharing the project’s findings.

This project is an initiative of the Institut du véhicule innovant, and is being carried out with Propulsion Québec, with Adria Power Systems, Dana TM4, Fournier & Fils and Nouveau Monde Graphite as industrial partners and National Research Council Canada (NRC) and CANMETMines as research partners. The project is made possible through the financial support of the Clean Growth Program in the natural resources sectors, the Innov-R program, and the programme d’appui à la recherche et à l’innovation du domaine minier (PARIDM – support program for research and innovation in the mining sector). The project is also receiving funding from the Financial Support for Northern Initiatives program and the Industrial Research Assistance Program (IRAP).

We would also like to thank Uniroc for allowing us to conduct on-site testing.

The detailed testing conducted on the electric vehicle demonstrates that it is well-suited for the requirements of open pit mining in Quebec. Despite a higher gradient in mines, we estimate a range of 3.5 hours for one hour of charging, consistent with the initial objectives. This underscores the need to carefully plan operations to optimize the truck’s use.

In terms of performance, the electric vehicle rivals diesel trucks, specifically regarding climbing speed, which is essential to productivity. However, its load capacity drops by 11.7% when transporting materials and depending on the charging stations, its operating cycle is limited. Economically, while it is more expensive to purchase an electric vehicle, operating costs are comparable, if not lower, than those of diesel vehicles, especially with an optimized charging infrastructure.

Our experience suggests that the mining sector is also ready to adopt this technology, with some minor adjustments. However, there are still some challenges, specifically regarding the charging infrastructure. It is essential to accurately forecast the energy needs of each site and check the availability of power input. Depending on specific needs, higher charging power might be necessary, which might not always be compatible with the existing power input. In addition, reliability is still an issue. While most of the problems can be resolved in an improved version, the current vehicle was designed to prove its technological viability without optimizing it for commercial production. To ensure its commercial success, it is, therefore, essential to collaborate with a manufacturer capable of bringing this technology to a higher maturity level.