Underground mining has always relied on diesel-powered machines for power and endurance. These machines get the job done, but they also produce emissions, have high fuel costs and create harsh working conditions.
As environmental pressures rise, battery-electric vehicles (BEVs) have become a promising alternative. Still, making the shift comes with obstacles that mines must overcome to fully stick to this new path.
The Promise of BEVs in Mining
BEVs bring clear performance and environmental advantages to underground mines. Electric engines reach up to 90% efficiency, while conventional diesels average only around 30%. That difference leads to significant energy savings, less wasted heat, and better performance in highly demanding environments.
More importantly, BEVs create healthier, safer conditions for workers. They eliminate diesel exhaust and particulate matter, reducing the burden on ventilation systems and improving air quality in enclosed spaces. They also cut underground heat and noise, creating more comfortable and less hazardous working environments. On a larger scale, BEVs align with global sustainability goals. Studies show that electric vehicles produce fewer emissions than traditional vehicles. This reduction makes electric vehicles a clear sustainability upside for mines and a strategic investment for long-term competitiveness.
Key challenges and how to overcome them
BEVs may offer big gains, but underground adoption brings technical, operational and financial hurdles.
Infrastructure limitations
Infrastructure is often the first barrier to adoption. While global EV market sales are expected to make up 27% of total vehicle sales by December, this will increase the demand for chargers, grid capacity, and battery supply. The problem for mining operations is that this can lead to higher upfront costs for charging stations and a greater need for local power upgrades. Remote sites feel this acutely because charging infrastructure is still lacking in many places, and keeping up with demand is difficult. The best way to reduce risk is to work with utilities and Original Equipment Manufacturers (OEMs) early to map power needs and explore microgrids. On-site renewables plus battery storage should also be considered to avoid costly surprises later.
Battery performance
Batteries can lose range quickly under heavy loads, and frequent fast charging speeds up wear. In practice, some heavy-use battery packs fall to about 75% capacity over time, which can force earlier replacements and disrupt schedules. Keep good battery-management systems in place and consider swappable packs for high-use equipment. Adding routine state-of-health checks is also essential to catching problems before they halt operations.
Operational adjustments
Charging and energy management can quickly become the biggest challenge in mining operations. If trucks and loaders all need power at the same time, chargers become bottlenecks and peak electricity demand spikes. If a machine needed for a sudden high-energy task is low on charge, it will sit idle and cause delays. The solution is to treat charging like another production process. Schedule bulk charging in predictable low-demand windows, such as overnight or shift changes. Chargers should also be close to work faces or maintenance bays to cut travel time, so charging becomes planned.
A practical path forward for BEV adoption
BEVs can make mining cleaner, quieter, and more efficient, but those gains only arise when mines pair the right gear with realistic planning. Start small and partner on ruggedised batteries and changing solutions. These steps will make changing and fleet management integration easy and turn adoption into a long-term advantage.
Author bio
Jane Marsh is a seasoned environmental journalist and the Editor-in-Chief of Environment.co, specialising in in-depth coverage of environmental trends, sustainability, and the evolving energy landscape. With her work featured on leading platforms like Renewable Energy Magazine, Manufacturing.net, and Nation of Change, Jane brings a keen perspective on the intersection of energy innovation and industry practices.