Driving cost efficiency in mining

Mining operations around the globe are under increasing pressure to control costs, meet tightening emissions regulations, and manage unpredictable fuel prices. In this context, electrification is rapidly emerging not only as an environmental objective, but as a smart commercial strategy. More specifically, retrofitting existing diesel-powered vehicles with electric drivetrains is proving to be a practical and financially compelling route to future-proofing mining fleets.

A new ABB whitepaper, ‘Achieving the COP28 UAE Consensus,’ underscores this shift. It demonstrates how retrofitting diesel vehicles with electric systems can dramatically reduce operating costs, increase equipment life, and help mines navigate the changing regulatory landscape – all without the heavy capital outlay associated with fleet renewal.

Electrification: A financially sound strategy

Fuel and maintenance costs represent a significant portion of a mine’s operational expenditure. Diesel engines are not only fuel-intensive, but also mechanically complex, leading to frequent breakdowns and high servicing costs. By contrast, electric drivetrains offer a leaner, cleaner alternative. They reduce heat, vibration, and mechanical wear – all of which contribute to greater reliability and lower maintenance bills.

More importantly, retrofitting extends the lifecycle of existing assets. Rather than investing in costly new electric vehicles, mines can upgrade their current fleet. This approach drives return on investment (ROI) forward, especially when factoring in long-term fuel savings, reduced downtime, and compliance benefits.

As ABB’s whitepaper notes, vehicle electrification delivers “measurable improvements in total cost of ownership (TCO) from day one.” Every kwh saved is one we do not need to generate – cutting emissions, easing grid pressure, and saving money. Real-world deployments of ABB’s solutions across mining operations have demonstrated precisely that – combining drivetrain retrofitting with intelligent energy management to lower costs and enhance performance.

Proven retrofit technologies in action

ABB’s electric drivetrain systems are designed for flexibility, with the ability to retrofit a wide range of mining vehicles, including haul trucks, loaders, and support machinery. These systems are complemented by smart charging strategies and energy management tools that ensure optimal battery usage and minimise peak load stress.

Digitalisation also plays a critical role. ABB’s condition monitoring and predictive maintenance platforms provide operators with real-time data insights, allowing for proactive repairs and significantly reducing unplanned downtime. These digital tools enhance uptime and reliability, making retrofits not just a stopgap, but a strategic upgrade.

The evidence is already compelling: retrofitted fleets are showing significant reductions in fuel consumption, maintenance costs, and associated emissions – all while maintaining, and often enhancing, vehicle performance.

Regulatory support and industry leadership

Electrification is also gaining momentum thanks to supportive policy environments. Governments worldwide are setting more ambitious emissions targets, with the mining sector squarely in focus. However, many are also providing incentives to accelerate the adoption of clean technologies – including retrofits.

ABB is actively engaging with policymakers to ensure that retrofit strategies receive equal recognition to new-build electrification in funding frameworks and emissions regulations. As highlighted in the whitepaper, this balanced approach will be essential to enable widespread, cost-effective decarbonisation of mining fleets.

This week’s IEA Annual Global Conference on Energy Efficiency is set to underscore the importance of private-sector leadership, in collaboration with governments, to scale energy-efficient solutions rapidly. As a leading technology partner, ABB will continue to advocate for solutions that align environmental responsibility with operational excellence.

Electrify to thrive: The path forward

For modern mining operators, electrification through retrofits is a pragmatic response to today’s economic and regulatory challenges. It's not simply a move towards planet stewardship – it is a decisive step towards leaner, cleaner, more resilient business models.

With mature technologies, proven cost benefits, and growing policy alignment, the case for electrifying mining fleets has never been stronger.

Read the article online at: https://www.globalminingreview.com/special-reports/11062025/driving-cost-efficiency-in-mining/