Vale, a leading mining company, is partnering with Caterpillar to introduce a massive 240-ton battery-electric haul truck, aiming to reduce carbon emissions significantly at its mining sites by 2030.
Vale and Caterpillar have an arrangement whereby the latter company will test alcohol-powered trucks, V2G/V2x energy transfer systems, and heavy-duty battery-electric mining trucks like the Caterpillar 793 BEV. Through these tests, Vale can determine what equipment is best suited to meet its aggressive targets of removing all its net emissions by 2050 and reducing direct and indirect carbon emissions by 33% by 2030.
Considering Brazil’s unique automotive landscape, where most vehicles run on either pure ethyl alcohol/ethanol (E100) or “gasohol” (E25), this initiative aligns well with existing infrastructure. “We are developing a portfolio of options to decarbonize Vale’s operations, including electrification and the use of alternative fuels in the mines. The most viable solutions will be adopted,” explains Ludmila Nascimento, Vale’s Energy and Decarbonization Director. She adds, “We believe that ethanol has great potential to contribute to the 2030 target because it is a fuel that has already been adopted on a large scale in Brazil, with an established supply network.”
Vale plans to test the 240-ton Cat 793 battery-electric haul truck at its Minas Gerais operations and evaluate energy transfer solutions at its Pará sites over the next two to three years. Additionally, Caterpillar and Vale will jointly study the feasibility of a dual-fuel (ethanol/diesel) solution for existing internal combustion engine (ICE) assets.
As the world’s largest producer of iron ore and nickel, Vale is committed to investing between $4 billion and $6 billion to meet its 2030 decarbonization target.
The Cat 793 haul truck, which debuted in 2022, demonstrated impressive capabilities on a 4.3-mile test course at Caterpillar’s Tucson proving grounds. Fully loaded, the truck reached a top speed of over 37 mph (60 km/h) and successfully climbed a 10% grade for a full kilometer at 7.5 mph. The truck used regenerative braking during the descent to recharge its battery, completing multiple testing cycles with the remaining charge.
Caterpillar has not disclosed detailed specifications, but the performance of the Cat 793 indicates significant potential for electric equipment in mining operations. “Electric equipment and mining go together like peanut butter and jelly,” commented an industry observer. “In confined spaces, the carbon emissions and ear-splitting noise of conventional mining equipment can create dangerous circumstances for miners and operators.”
Through collaborations with companies like Vale, Caterpillar hopes to show that electric machinery can operate on par with, if not better, conventional internal combustion engines. The industry’s transition to more environmentally friendly methods and providing a cleaner, safer working environment for miners are greatly aided by this collaboration.