Editions

Contents

Testing & tagging in mining Truflo Pumping Systems – Dependable mine dewatering systems Fuelling success with Body Armour McLanahan – Maximum production, unwavering support Flexible online and face to face training with experienced accredited provider Machining and fabrication service since 1980s Optimising mining operations with integrated IT/OT solutions Lighten the load — literally and safely Half-year results glitter for Westgold Miller Made for the Mine Site Broons: the crushing and compaction specialist Welding Industries Australia – Miller – Made for the mine site Fortescue swoops up Red Hawk Growing critical minerals processing power in WA Atlas achieves first production Custom Buckles Australia Crusher Screen Sales & Hire DTN – Lean on us – Gain trusted weather insights and intelligence AUSTLIFT® – Chain Block Series Aussie Pumps – Aussie Extreme Crusader Hose – Experience the innovation in action UQ Start-UP Unlocks Copper Mining matters 100 years strong at Ulan Coal Dartbrook hits the bullseye Aurelia Metals ascends to the peak BHP Yandi – Leading the way in electrification Innovation and safety go green NSR Indigenous: Empowering Australia’s mining industry Innovation and its role in improving ESG outcomes Brooks brings in the big guns Collaborative approach to mining research bears fruit Flood rescue: Aussie gears up New Acland thrives in 2025 Tanami: Newmont’s Tier 1 titan Innovation in the Isaac Region BHP builds up for big finish in FY25 South32’s Worsley receives key approval Pilbara Minerals acquires Latin Resources Australia pours $1b into green iron Engineering mining’s future

BHP Yandi – Leading the way in electrification

(Image source: BHP)

The Yandi mine, located 178km north-west of Newman in the Pilbara region of WA, is one of the five mining hubs comprising BHP’s (ASX: BHP) WA Iron Ore (WAIO) operations. Commencing production in 1992, Yandi became the second second WA-based iron ore mine to achieve 1bt of ore produced in its lifetime in 2017.

Since then, the mine has begun ramp down activity. But the mine is still playing a pivotal role for BHP, especially on the way to net zero.

BHP’s first entry into electrification

BHP Excavator
(Image source: BHP)

In August 2024, BHP took a major step on its decarbonisation journey with the deployment of its first electric excavator to Yandi.

Instead of a diesel engine, the R 9400 E Liebherr electric excavator has an electric motor, with power fed to the machine by a trailing cable.

Equipped with Liebherr’s autonomous cable reeler for optimal on-site mobility, this innovation boosts productivity and operator safety.

WA Iron Ore (WAIO) asset president Tim Day says a reduction in diesel is essential to reduce operational greenhouse gas (GHG) Scope 1 and 2 emissions by at least 30% by FY30 from FY20 levels and achieve net zero operational GHG emissions by CY50.

“Electrification of our fleet is our preferred solution to displace greenhouse gas emissions from using diesel — from trucks to trains to excavators — we’re working hard to electrify our equipment,” he said.

“Collaborations with partners like Liebherr are critical to accelerate development of the technology required to reduce diesel emissions, while ensuring we continue to improve the safety and productivity of our operations.”

Liebherr-Australia sales and marketing executive general manager Brian Boitano says the R 9400 E is a testament to Liebherr’s dedication to providing innovative and efficient zero emission solutions for the mining sector.

“We are thrilled to partner with BHP, a forward-thinking industry leader, to introduce our proven electric excavators into their operations and to help them move forward in their decarbonisation journey,” he said.

BHP’s strategy aims to decarbonise mining equipment by switching from diesel to renewable electricity or other low to zero GHG emissions power. Renewable electricity is not purchased through the market as WAIO is not connected to an existing grid, so The miner is working through the best way to introduce the large volumes of renewable or other low to zero emissions power needed.

This includes a number of actions to decarbonise sites, with a focus on maximising renewable electricity and other sources of low to zero GHG emissions power, diesel displacement through electrification and working to manage fugitive methane emissions.

Operational decarbonisation

Yandi
(Image source: BHP)

Yandi has served as an opportunity for the company to learn more about adoption and de-risking of new technology which will benefit future electrification efforts.

According to BHP, the company’s biggest remaining source of operational GHG emissions is diesel, making electrification a necessary innovation for the miner.

In the company’s Climate Transition Action Plan 2024 (CTAP), BHP says it anticipates electric haul trucks (compared to current state diesel haul trucks) will have superior fuel-to-wheel energy efficiency and trucks are able to drive faster on trolley assist than on diesel motors.

However, significant operational challenges exist, including fleet management, integration of a mix of static and dynamic charging, how electrification impacts mine design and mine planning and risk management of new technologies.

“Improvements to battery size, cost, weight, capacity and replacement cycles are also needed before large-scale adoption,” BHP said in its 2024 CTAP.

“We expect to displace diesel primarily via electrification of mining equipment/vehicles (including locomotives) and the associated use of low to zero GHG emissions electricity sources.”

BHP expects additional benefits of electrification over diesel including improved maintenance performance; elimination of diesel particulate matter; reduction in heat, noise and vibrations and compatibility with autonomous driving technology.

The electrification of mining equipment and vehicles will also be a change to the way BHP operates at sites.

BHP recognises the advantages of a site-by-site approach to learn and adapt plans as it progresses and to identify any implications of these changes to the safety of its teams and the productivity of operations.

Trials, pilots and other supporting studies aim to understand and address a wide and essential range of variables, including additional safety considerations; performance in high temperature, high altitude, dusty and rough environments; battery lifecycle and recycling; high-power static and dynamic charging; mixed diesel and electric mining equipment/vehicles and integration with autonomous haulage.

In the company’s 2024 CTAP, BHP says it expects original equipment manufacturers to be ready to produce electric mining equipment/vehicles at scale in the late 2020s.

“Electrification will require a significant increase in high voltage electrical infrastructure for trailing cables, trolley lines, fast chargers and other infrastructure that will need to

be safely integrated into our operations,” BHP said in its 2024 CTAP.

BHP expects the WAIO asset to likely be its first operated asset to progressively roll-out electric haul trucks and excavators towards the end of the 2020s.