Decarbonising mining is challenging. While electric and hydrogen solutions show promise, they are still in development and not yet reliable for heavy equipment in demanding environments due to tough conditions and varying infrastructure across regions.
Adding to these challenges, miners face a critical task in needing to balance decarbonisation with any impact to productivity and overall total cost of operation (TCO). These factors combined make the energy transition for the sector a complex puzzle.
Over the years, the mining industry has explored many different potential decarbonisation pathways. More recently, hybridisation has emerged as a standout solution with a bright future in bridging towards an effective energy transition.
Benefits of hybrid
Hybrids combine a proven internal combustion engine with battery power, offering more power, better fuel efficiency, and lower emissions. Miners achieve the same power as larger engines while using less fuel, reducing operational costs. This enhances fleet efficiency, productivity, and sustainability, with ongoing improvements as technology evolves. It is a smart investment during the transition to zero-emission haulage. To fully realise these benefits, we must evaluate real-world performance.
First hybrid field test shows early success
Cummins’ first-fit hybrid powertrain pilot began in 2024 with NHL. Central to this project has been the hybrid NHL NTH260, a 220 t payload mining truck, which was deployed for field testing at the Baiyun Iron Mine of Baogang Group in China during March 2024, with initial tuning testing taking place over May and June. This was followed by operation tests 12 hours a day, 7 days a week, which ran from July to the end of November.
Testing period data showed clearly the benefits of using hybrids. The truck utilised hybrid capabilities to operate for over 2500 hours, with a 15% to 20% reduction in fuel consumption and therefore carbon emissions achieved. The hybrid system proved highly reliable, paving the way for testing over 24-hour operation, 7 days a week, which began in December last year.
Installing hybrid capabilities to this test truck enabled a downsizing of the engine, from the 2500 hp QSK60 to the current 2000 hp two-stage Cummins QSK50.
Reflecting on the project, SUN Yongqiang, a mine operator at Baiyun, said: “It was amazing to see improvements in truck performance using these technologies, with measurable differences made to productivity and cost. It gives me great confidence that hybrids are paving the way forward as a bridge solution.”
NHL Deputy GM, ZHAO Xinchun, added: “The results from this pilot speak for themselves. This is an exciting prospect for us and our miners, demonstrating that hybrids are a great power solution for now and into the future. It was great to collaborate with Cummins and see how we can make impactful steps towards decarbonisation.”
Acquisition of First Mode
Cummins is strengthening its position in hybrid power solutions further with the acquisition of First Mode assets. First Mode is known a leader in retrofit hybrid solutions for mining applications.
Molly Puga, General Manager of First Mode, said: “By integrating First Mode’s innovative start-up energy with Cummins’ global scale and expertise, we’re enhancing our ability to provide decarbonization solutions that meet miners’ needs to drive operational costs down today. Together, we’re thrilled to advance a sustainable future and expand Cummins’ comprehensive hybrid portfolio.”
The First Mode retrofit kit delivers immediate fuel savings and reduces emissions by up to 25% with minimal changes to an existing ultra-class electric drive haul truck and requires no additional infrastructure. Cummins cites extensive pilot opportunities for 2025 and 2026, followed by scaled production in 2027 and beyond.
The future of hybrids on the road to carbon neutrality
Mining Innovation Manager John Essegbey emphasises that Cummins believes there is no one-size-fits-all approach to decarbonisation, including hybrids. Cummins, with former First Mode experts, is evaluating long-term technology options for advanced hybrids that improve value across different use cases. Cummins will continue collaborating with leading OEMs to deliver a portfolio of hybrid solutions for deployment at scale, including first-fit and retrofit solutions for progressive fleet decarbonisation.
Cummins will be speaking on this topic at The Electric Mine 2025 in Santiago, Chile.