Quiet giants: How electric machines can redefine surface mining

There has been much written about the transition of underground fleets from diesel to electric. Largely, the impetus for this trend has been credited to the decrease in ventilation costs and impact on workers’ health inherent with battery electric equipment. These adoption pressures do not exist in surface mining in the same way but still, surface mining is on the cusp of a major transformation as electrification moves from the underground to the open pit. The diesel-dominated fleets that have powered surface operations for decades are now facing different pressures to evolve, driven by a mix of regulatory, economic, environmental, and social forces. Electrification is now emerging as a strategic priority for surface operators looking to future-proof their assets, reduce costs, and meet increasingly ambitious emissions targets. With proven technologies rapidly maturing over the last decade and innovative companies stepping into the space, the path forward is becoming more defined, and Canada has a significant role to play.

The motivations for electrifying surface fleets are multi-faceted but reducing carbon emissions is chief among them. Governments around the world, including Canada, are enforcing stricter emissions regulations, and major mining companies are setting aggressive net-zero goals in response to investor pressure and stakeholder expectations. Electrification offers a direct means of addressing Scope 1 emissions, particularly from haulage and support vehicles, which collectively represent a large share of a mine’s carbon footprint. However, transitioning to battery electric equipment is not just about optics, it is about aligning core operations with climate policy and staying ahead of tightening regulatory frameworks.

Beyond compliance, cost efficiency is a powerful driver of electrification in surface mining. According to a report 2021 by Coencorp, diesel fuel alone can account for 3% to 10% of a mine’s total operating expenditure, and it is one of the largest operating expenses for mines. Battery electric vehicles (BEVs), while still carrying a higher upfront capital cost, can deliver significant savings over their lifespan. With fewer moving parts than internal combustion engines, BEVs are cheaper to maintain, require less downtime, and eliminate the need for large quantities of fuel and lubricants. When paired with renewable energy sources for charging, they offer a stable and often cheaper energy profile that can give firms a valuable edge in increasingly competitive commodity markets.

Electrification also addresses growing expectations around worker health and community safety. Diesel particulate matter (DPM) has long been a concern in mining environments, and reducing emissions at the source creates healthier conditions for operators and maintenance staff alike. DPM remains a significant health concern in open-air surface mining operations owing to its fine particle size and chemical composition. Despite the open environment, workers are still at risk of inhaling these particles, which can penetrate deep into the lungs and enter the bloodstream. Quieter electric vehicles reduce noise pollution, improve working conditions, and strengthen relationships with nearby communities. In regions where mines coexist with Indigenous communities or environmentally sensitive areas, BEVs offer a pathway to reduced environmental disturbance, which can ease permitting and support the long-term viability of a site.

Operationally, BEVs have begun to prove their worth. Electric drivetrains offer instant torque and smooth acceleration, which can improve productivity in key tasks like hauling and earth moving. In a recent blog post, electrification expert Eric Zeng noted that electric mining trucks can experience a 40% boost in acceleration during loaded starts and a 25% increase in climbing speed compared to their diesel counterparts. Also, with fewer points of mechanical failure, BEVs contribute to higher fleet availability, and they integrate well with emerging technologies such as automation and fleet telematics. These advantages are particularly valuable as mines confront growing skill shortages and seek to optimize operations through digital transformation.

Despite these benefits, challenges remain. Battery capacity continues to limit the deployment of BEVs in surface haul trucks, and the infrastructure required to support fast charging at scale is not yet widely available. Solutions like the ABB eMine FastCharge or Eaton’s Green Motion EV chargers are aiming to solve this issue and there will be undoubtedly more high-tech innovation in this space soon. Remote sites with limited grid access will also need creative solutions including microgrids, hybrid systems, and modular charging stations to make electrification feasible. Cold-weather performance is another hurdle, particularly in northern regions where batteries may lose efficiency and require robust thermal management systems. That said, progress is being made on all fronts, with OEMs, utilities, and mining companies collaborating to overcome these barriers.

Canada, with its history of innovation in underground mining and electrification, is playing a leading role in this transition. Companies based in mining hubs like Sudbury are leveraging their underground expertise to tackle the surface challenge. Among them is MacLean Engineering, a well-established OEM that has made significant inroads with battery electric solutions in underground environments. With the launch of its new surface mining division, MacLean is extending its electrification know-how to open-pit operations, eventually offering a suite of purpose-built support vehicles and engineering solutions tailored for surface applications.

MacLean’s move into surface electrification reflects a broader industry trend: the recognition that decarbonization is not a luxury but a necessity. Drawing on decades of experience designing rugged, mine-ready vehicles, MacLean is well-positioned to support operators looking to electrify support fleets, from service trucks to water carts to personnel carriers. Their entry into this space is timely, offering mining companies a credible, Canadian-made alternative as they plan for a low-emissions future. As surface mines begin the long transition away from diesel, partnerships with experienced OEMs will be essential in making the shift efficient, safe, and economically viable.

The electrification of surface mining is no longer a theoretical aspiration; it is a practical strategy gaining real traction. With compelling benefits across cost, safety, environmental performance, and social license, the case is becoming clear. While technical and logistical hurdles persist, they are shrinking with every new deployment and demonstration project. Thanks to creative engineering and a strong commitment to innovation, Canada is helping to power the next phase of surface mining as a clean, quiet, and electric endeavour. The only question that remains is how fast operators are willing to make the leap.

Steve Gravel is the manager of the Centre for Smart Mining at Cambrian College.

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