Hitachi Construction Machinery and ABB jointly developed the EH4000AC-3 full battery rigid dump truck. This breakthrough is a significant step forward for the mining sector. This cutting-edge vehicle is a natural extension of the current EH4000AC-3 model platform. It acts as a technological testbed to realize zero-emission operations. The trial of this ultra-large dump truck started in June 2024 at the Kansanshi mine. It will probably remain that way until at least the end of 2025.
The EH4000AC-3 operates at a nominal test payload of 220 tonnes. It offers a trolley charging option that allows for zero emissions, cost-efficient operation while pulling heavy uphill in both directions under a trolley line. With this creative truck, you can see the real power of collaboration between Hitachi and ABB. Their collaboration first started with battery design in 2020, officially starting development in 2021 after an agreement was signed.
Features and Performance
The EH4000AC-3 full battery dump truck shines nonetheless, mostly because of its zero-emission credentials. It uses a retractable twin pantograph solution to make a connection with overhead trolley wires, allowing for fast and effective charge while on the move. Its battery can be charged and discharged in six minutes at a super fast 10C rate. This capability is especially useful in dynamic charging environments such as those found in mining operations.
“The main advantage of this battery is its exceptionally high-power density and C-rate, which enable charging while the truck is in operation under the trolley line,” stated Thierry Jenelten from ABB. This added capability means that the truck in addition to being able to handle the heaviest loads possible is able to improve productivity by reducing downtime.
Additionally, the truck’s battery has a very long cycle life, rated at up to 40,000 full charge-discharge cycles. This longevity leads to a very low total cost of ownership, providing an attractive and economical alternative to mining operations. “With a long cycle life of up to 40,000 full charge-discharge cycles, LTO batteries ensure a low total cost of ownership over their lifespan,” Jenelten added.
Trial at Kansanshi Mine
The Kansanshi mine in Zambia has been identified as an ideal testing ground for the EH4000AC-3 due to its landscape and electricity sources. Run as a real world, live trial the aim is to test operational efficiency at an operational scale before full commercialisation. “The aim of the proof of concept trial is to test the truck under ‘real-world’ conditions to ensure that it operates as it should on an actual mine site,” said a spokesperson from Hitachi Construction Machinery.
During Runner’s trial, regenerative electric truck brakes have blown them away, returning more energy than they ever figured on. The way the truck operates during this period has a major effect on the energy efficiency of the vehicle and its free energy source.
“First, the regenerative electric brakes provide more energy than previously expected, and how the truck is operated during this time can make a significant impact on free energy supply,” emphasized the spokesperson.
Future Developments
Moving forward, Hitachi and ABB intend to push the EH4000AC-3’s performance level even higher. Future iterations would seek to offer the same or better payload capacity as their diesel counterparts but still offer increased efficiencies. “The main challenge lies in balancing battery capacity, truck autonomy and payload to achieve the lowest possible cost per tonne moved,” noted ABB.
In addition to building out more capacity, calculations will be modified to drive and charge percentages. This will allow for new shorter-distance charging rainbow routes and offer more flexibility for customer operations. “Second, a variation to charge and drive percentages will be made in the future to allow for shorter-distance charging routes and provide more versatility to customer’s operations,” the spokesperson explained.
Their innovative partnership underscores the importance both Hitachi Construction Machinery and ABB place on promoting safe and sustainable mining solutions. Both companies are addressing the challenge of scaling next gen battery tech to heavier work. All have an eye toward real world applications that improve their operational efficiencies while helping the environment.
“The landscape and electricity sources in Zambia, as well as FQM’s experienced trolley truck operational implications and our long-standing partnerships, were key decision-making aspects for us,” stated a representative from Hitachi.