IDEAS home Printed from https://ideas.repec.org/a/gam/jeners/v17y2024i6p1494-d1361184.html

Energy Consumption and Battery Size of Battery Trolley Electric Trucks in Surface Mines

Author

Listed:
  • Haiming Bao

    (School of Mechanical and Mining Engineering, The University of Queensland, Brisbane 4072, Australia)

  • Peter Knights

    (School of Mechanical and Mining Engineering, The University of Queensland, Brisbane 4072, Australia)

  • Mehmet Kizil

    (School of Mechanical and Mining Engineering, The University of Queensland, Brisbane 4072, Australia)

  • Micah Nehring

    (School of Mechanical and Mining Engineering, The University of Queensland, Brisbane 4072, Australia)

Abstract

Mining production, being one of the most energy-intensive industries globally, consumes substantial amounts of fossil fuels and contributes to extensive carbon emissions worldwide. The trend toward electrification and advanced developments in battery technology have shifted attention from diesel power to battery alternatives. These alternatives are appealing, as they contribute to decarbonisation efforts when compared to conventional diesel trucks. This paper presents a comprehensive review of recent technological advancements in powertrains for Mining Haulage Truck (MHT). It also compares these configurations based on mining system-level considerations to assess their future potential. The evaluated configurations include Diesel-Electric Truck (DET), Trolley Assist Truck (TAT), Battery-only Truck (BOT), Battery Trolley with Dynamic charging truck (BT-D), and Battery Trolley with Stationary charging truck (BT-S). According to the analysis, the energy demand for on-board diesel or battery power (excluding trolley power) in these alternative options is as follows: DET—681 kWh, BOT—645 kWh, TAT—511 kWh, BT-S—471 kWh, and BT-D—466 kWh. The paper also illustrates the theory of battery size design based on the current battery technology, battery material selection, battery package design, and battery size selection methods. In the case of tailored battery size selection, BOT, BT-D, and BT-S configurations require LiFePO 4 (LFP) battery masses of 25 tonnes, 18 tonnes, and 18 tonnes, respectively. Based on a techno-economic assessment of battery MHT alternatives with a future perspective, it has been determined that BT-D requires the lowest amount of on-board battery energy. Furthermore, over a span of 20 years, BT-S has demonstrated the lowest on-board battery cost.

Suggested Citation

  • Haiming Bao & Peter Knights & Mehmet Kizil & Micah Nehring, 2024. "Energy Consumption and Battery Size of Battery Trolley Electric Trucks in Surface Mines," Energies, MDPI, vol. 17(6), pages 1-23, March.
    • Handle: RePEc:gam:jeners:v:17:y:2024:i:6:p:1494-:d:1361184
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/1996-1073/17/6/1494/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/1996-1073/17/6/1494/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Igogo, Tsisilile & Awuah-Offei, Kwame & Newman, Alexandra & Lowder, Travis & Engel-Cox, Jill, 2021. "Integrating renewable energy into mining operations: Opportunities, challenges, and enabling approaches," Applied Energy, Elsevier, vol. 300(C).
    2. Feng, Yanbiao & Dong, Zuomin, 2020. "Integrated design and control optimization of fuel cell hybrid mining truck with minimized lifecycle cost," Applied Energy, Elsevier, vol. 270(C).
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Feng, Juqiang & Cai, Feng & Zhao, Yang & Zhang, Xing & Zhan, Xinju & Wang, Shunli, 2024. "A novel feature optimization and ensemble learning method for state-of-health prediction of mining lithium-ion batteries," Energy, Elsevier, vol. 299(C).
    2. Pruethsan Sutthichaimethee & Grzegorz Mentel & Volodymyr Voloshyn & Halyna Mishchuk & Yuriy Bilan, 2024. "Modeling the Efficiency of Resource Consumption Management in Construction Under Sustainability Policy: Enriching the DSEM-ARIMA Model," Sustainability, MDPI, vol. 16(24), pages 1-17, December.
    3. Chenghao Lyu & Nuo Lei & Chaoyi Chen & Hao Zhang, 2025. "A Hierarchical Evolutionary Search Framework with Manifold Learning for Powertrain Optimization of Flying Vehicles," Energies, MDPI, vol. 18(13), pages 1-20, June.
    4. D. Biniaris & G. Xiroudakis & G. Saratsis & G. Exadaktylos & EA Varouchakis, 2025. "Minimization of CO2 Emissions in Openpit Mines by Using Stochastic Simulations," Circular Economy and Sustainability, Springer, vol. 5(3), pages 2317-2345, June.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Mesa, Jaime A. & Hincapie-Florez, Diego & Bobadilla-Vasquez, Melkis & Corredor, Lesme & Pupo-Roncallo, Oscar & Gonzalez-Quiroga, Arturo, 2025. "Assessing technological trends in mining fleet energy management toward sustainable mineral extraction," Resources Policy, Elsevier, vol. 109(C).
    2. Aihua Tang & Lin Yang & Tao Zeng & Quanqing Yu, 2022. "Cascade Control Method of Sliding Mode and PID for PEMFC Air Supply System," Energies, MDPI, vol. 16(1), pages 1-13, December.
    3. Femi-Olagundoye Mercy, 2024. "Exchange Rate Management and Sectorial Export-Financing in Nigeria," International Journal of Research and Innovation in Social Science, International Journal of Research and Innovation in Social Science (IJRISS), vol. 8(8), pages 4332-4350, August.
    4. Sanghyun Yun & Jinwon Yun & Jaeyoung Han, 2023. "Development of a 470-Horsepower Fuel Cell–Battery Hybrid Xcient Dynamic Model Using Simscape TM," Energies, MDPI, vol. 16(24), pages 1-22, December.
    5. Oluwaseye Samson Adedoja & Emmanuel Rotimi Sadiku & Yskandar Hamam, 2025. "Multicriteria Decision-Making for Sustainable Mining: Evaluating the Transition to Net-Zero-Carbon Energy Systems," Sustainability, MDPI, vol. 17(10), pages 1-32, May.
    6. Abbas, Khizar & Han, Mengyao & Xu, Deyi & Butt, Khalid Manzoor & Baz, Khan & Cheng, Jinhua & Zhu, Yongguang & Hussain, Sanwal, 2024. "Exploring synergistic and individual causal effects of rare earth elements and renewable energy on multidimensional economic complexity for sustainable economic development," Applied Energy, Elsevier, vol. 364(C).
    7. János Szanyi & Ladislaus Rybach & Hawkar A. Abdulhaq, 2023. "Geothermal Energy and Its Potential for Critical Metal Extraction—A Review," Energies, MDPI, vol. 16(20), pages 1-28, October.
    8. Zhou, Xingyu & Guo, Yuekai & Hao, Wenmei & Zhang, Xingyong & Wang, Wenwei, 2025. "Kinematic state adaptive based novel powertrain for the next generation of vehicle electrification: Design optimization and simplification," Applied Energy, Elsevier, vol. 395(C).
    9. Alberto Biancardi & Idiano D’Adamo & Ernesto D. R. Santibanez-Gonzalez & Joaquín Francisco Varela Bascur, 2025. "A Flexible and Circular Management of Copper in Chile: New Perspectives Toward Sustainable Development," Global Journal of Flexible Systems Management, Springer;Global Institute of Flexible Systems Management, vol. 26(4), pages 813-837, December.
    10. Zhang Zheng & Liu Zhe & Wang Huihui, 2026. "The Relationship Between Institutional Quality, Renewable Energy Investment, Financial Development, and Ecological Hazards: Evidence from ASEAN Countries," Journal of the Knowledge Economy, Springer;Portland International Center for Management of Engineering and Technology (PICMET), vol. 17(1), pages 2153-2181, February.
    11. Xun, Qian & Murgovski, Nikolce & Liu, Yujing, 2022. "Chance-constrained robust co-design optimization for fuel cell hybrid electric trucks," Applied Energy, Elsevier, vol. 320(C).
    12. Zhou, Xingyu & Guo, Yuekai & Huang, Youliang & Zhao, Nianhan, 2025. "Driving cycle reproduction supported deep learning co-optimization of freight EV powertrains in stochastic operation environments," Energy, Elsevier, vol. 340(C).
    13. Lei Zhang & Liang Xie & Xianzhong Mu & Guangwen Hu, 2025. "Trade and the Sustainable Energy Transition: Exploring the Impact of Trade on Total Factor Renewable Energy Efficiency," Sustainability, MDPI, vol. 17(4), pages 1-27, February.
    14. Artur Dyczko & Kinga Stecuła & Lilianna Stańczak & Barış Aydın & Paweł Kamiński, 2024. "Process Approach in a Mining Company: LW Bogdanka S.A. Case Study," Sustainability, MDPI, vol. 16(20), pages 1-22, October.
    15. Ding, Hongbing & Dong, Yuanyuan & Zhang, Yu & Wen, Chuang & Yang, Yan, 2024. "Exergy performance analysis of hydrogen recirculation ejectors exhibiting phase change behaviour in PEMFC applications," Energy, Elsevier, vol. 300(C).
    16. Ma, Shuai & Lin, Meng & Lin, Tzu-En & Lan, Tian & Liao, Xun & Maréchal, François & Van herle, Jan & Yang, Yongping & Dong, Changqing & Wang, Ligang, 2021. "Fuel cell-battery hybrid systems for mobility and off-grid applications: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 135(C).
    17. Molina, S. & Novella, R. & Pla, B. & Lopez-Juarez, M., 2021. "Optimization and sizing of a fuel cell range extender vehicle for passenger car applications in driving cycle conditions," Applied Energy, Elsevier, vol. 285(C).
    18. Ma, Zhongjun & Zheng, Yanlong & Li, Jianchun & Zhao, Xiaobao & Zhao, Jian, 2024. "Enhancing rock breakage efficiency by microwave fracturing: A study on antenna selection," Energy, Elsevier, vol. 288(C).
    19. Raza, Syed Ali & Khan, Komal Akram, 2024. "Climate policy uncertainty and its relationship with precious metals price volatility: Comparative analysis pre and during COVID-19," Resources Policy, Elsevier, vol. 88(C).
    20. Torres, Cati & Valero, Alicia & Valero, Antonio & Naredo, José Manuel, 2026. "Squaring the circle of the circular economy. The need to properly account for scarcity to guide mineral resource management," Ecological Economics, Elsevier, vol. 240(C).

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jeners:v:17:y:2024:i:6:p:1494-:d:1361184. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.