Swedish metals maker Boliden, technology company ABB and original-equipment manufacturer Epiroc have successfully deployed the first fully battery-electric truck trolley system on an 800-m-long underground mine test track in Sweden, with a 13% incline.   

ABB says the achievement of the collaboration in Boliden’s Kristineberg mine, in northern Sweden, marks a critical moment for the mining industry as it continues to face rising pressures to balance increased outputs of critical minerals and metals with lower carbon emissions and energy use.

It notes that demand for minerals critical to society’s clean-energy transformation is predicted to increase between 1.5 and seven times by 2030 according to the International Energy Agency, making electrification a priority.  

In tandem with reducing carbon emissions, ABB explains that the electrification of mining also promises improved health and safety for the industry’s workforce.

By deploying this system, the collaboration partners aim to prove that the underground working environment can be significantly improved, with less emissions, noise and vibration, while reducing the total cost per ton. 

“Over the past three years, we have worked in close collaboration with the ABB and Epiroc teams to bring the electric mine of the future one step closer.

“The most important thing for us is of course that the technology works in our own operations, but we also see added value that we together with our partners can drive technology development so that the system can be used in other mines. We are proud to have taken this concept to a live instalment,” says Boliden GM for the Boliden Area Peter Bergman.

Each partner has provided a unique set of expertise to this development process.

Epiroc has added dynamic charging to its proven battery-electric Minetruck MT42 SG and battery system, and the trolley solution is equipped with ABB’s DC converter, HES880 inverters and AMXE motors to enhance the power.

The truck also features a trolley pantograph connected to an overhead catenary line, a concept which is highly suitable for long haul ramps. 

The electric trolley line gives additional assistance to the battery-electric mine truck on the most demanding stretches up-ramp while fully loaded, enabling further reach and battery regeneration during drift, which increases productivity for a mining operation. 

ABB created the infrastructure from grid to wheel, including the electric truck trolley system design and the rectifier substation for the test track. The definition of standards and vehicle interface was jointly developed by the project partners. 

ABB notes that the underground environment is a unique challenge.

To design a solution that could adapt to voltage fluctuations along the system, ABB collaborated with its partners to build a digital twin to simulate all scenarios.

The result is a dynamic trolley system, with intelligent switchgear, measurements and transparency with the in-built ability to adjust power where it is needed at any given moment.  

“Together, in close partnership we can accelerate the transformation and reach a steep curve in mining technology innovation like we have done in Kristineberg.

“In a short space of time, we have implemented and delivered technology to not only reduce carbon dioxide emissions, but substantially extend travel distance for battery-electric driven vehicles on heavy ramp haulage, reduce operating costs, and improve the health and safety of mining environments,” says Epiroc underground division president Wayne Symes.

“We are passionate and committed to creating real progress for the mining industry.

“Seeing the industry’s first battery electric truck trolley system live is not only the result of a collaborative achievement with Boliden and Epiroc, but it is truly an industry milestone. We launched the ABB eMine concept of methods and solutions to bring electrification to the whole mining operation, from the grid to the wheel, and the installation at Kristineberg demonstrates the power of these capabilities,” adds ABB mining global business line manager Max Luedtke.

This project is supported by funding from the Swedish innovation agency Vinnova and their initiative ‘Sustainable Industry’ and will contribute to Boliden’s vision to be the most climate-friendly and respected metals provider in the world. 

Boliden intends to implement a full-scale, autonomous electric-trolley system in the Rävliden mine, a satellite orebody and extension of the Kristineberg mine, and has placed an order for four Minetruck MT42 SG Trolley trucks from Epiroc.

The total distance will be 5 km at a depth of 750 m.

Once achieved, Rävliden is expected to have less carbon emissions compared with a mine using conventional technology. It will also be part of setting a standard for new mines, says ABB.