Liebherr’s cope with Australian mining large, Fortescue is making a fleet of large, zero-emission electrical autos designed to get rid of carbon emissions from operations by the tip of the last decade
Giant autos have lengthy been thought of essentially the most difficult to decarbonise, however a brand new partnership between Liebherr and Australian mining large Fortescue is demonstrating that large-scale electrification shouldn’t be solely attainable however economically viable. At $2.8 billion the Fortescue contract is the one largest tools deal in Liebherr’s 75-year historical past and Fortescue’s largest ever contract. The partnership encompasses 475 zero-emission machines: roughly 360 autonomous battery-electric vehicles, 55 electrical excavators, and 60 battery-powered dozers.
For Fortescue, the partnership is a cornerstone of its Actual Zero goal – eliminating carbon emissions from its Australian iron ore operations by 2030. Dr Andrew Forrest, Fortescue’s government chairman, frames this as each an environmental crucial and enterprise alternative. “The world wants Actual Zero now – it can not afford to attend,” stated Forrest in a presentation on the opening ceremony of Bauma in April. “The inexperienced options we want are right here at this time, and Fortescue Zero is supplying them and rolling them out throughout our large mining operations.”
On the coronary heart of the partnership is the T 264 Battery Electrical inflexible mine hauler. Richard Kraemer, haulage electrification options supervisor for Liebherr, explains the mixing: “Fortescue Zero is our battery energy system provider. They make all of the sub packs and all the mandatory elements that go along with it, which we combine into our truck.”
Fortescue began growing electrification options in 2022 when it purchased Williams Superior Engineering (WAE), the battery and know-how arm of Williams System One racing crew. In 2024 WAE was rebranded to Fortescue Zero, as a part of the corporate’s Actual Zero undertaking.
Fortescue Zero has developed a 3.2MWh battery system to energy Liebherr’s 240-tonne capability truck, with charging through three distinct strategies. The primary methodology is a static fast-charging answer, which might ship as much as 6MW of energy via an automatic robotic connection arm utilizing two Megawatt Charging System (MCS) connectors, with 30-minute quick charging capabilities.
A second charging choice is energy switch utilizing Energy Rail, which is an evolution of confirmed trolley bar know-how. “This takes the normal advantage of trolley help, which is completed via overhead traces, however does it via a sidemounted rail,” says Kraemer. “This optimises set up time, whereas offering an environment friendly technique of energy switch to the truck.”
Lastly, the truck is provided with regenerative braking know-how. “Whereas the truck is working downhill, in a typical diesel truck, that vitality could be launched via braking. Now it’s captured on the onboard battery energy system,” says Kraemer.
“The world wants actual zero now – it merely can not afford to attend”
Battery choices
Fortescue Zero has developed two battery configurations to handle completely different operational necessities. The vitality capability battery features “like an enormous gasoline tank,” offering longer working instances the place charging infrastructure could also be restricted. This model requires roughly one hour to cost and gives a lifecycle of two to 3 years with roughly 3,600 charging cycles.
Together with the T 264, the R 9400 E cable-powered electrical excavator is being produced as a part of the Liebherr-Fortescue partnership, with 55 machines set to be deployed
The ability battery expenses inside 12 minutes, designed for operations with available charging infrastructure. Whereas providing much less vitality storage, it offers extra frequent charging cycles and longer lifecycle. “That is the place you’d use the automated charging answer utilizing the robotic arm,” says Larissa Lunitz, head of public relations at Liebherr.
The twin battery configuration strategy offers flexibility, permitting websites to decide on the optimum answer based mostly on their particular infrastructure and operational necessities.
Rising OEM capability
Supporting this large fleet means Liebherr is making investments. “We’re on observe with our funding plans to develop our international infrastructure to make sure that we are able to accommodate the enlargement of our enterprise and supply our prospects with bigger portions and a wider vary of zero emission know-how,” says Michael Arndt, government vice chairman of service and high quality at Liebherr-Mining Gear.
The partnership with Liebherr additionally extends past Fortescue’s operations. Each firms have confirmed that their zero-emission mining ecosystem will turn out to be accessible to the broader mining business. “The know-how developed as a part of this record-breaking deal won’t solely assist our prospects alongside their decarbonisation journeys but in addition assist us honour our dedication to supply fully fossil gasoline free hauling, loading and dozing options by the tip of the last decade,” says Dr Lukowski, government vice chairman of gross sales and advertising and marketing at Liebherr-Mining Gear.
Forrest positions this transition as economically pushed slightly than purely environmental: “We’re not right here to be altruistic. We’re not right here to be philanthropic. We’ve received to pay the wages. We’re going to repay the development tools we purchase. Sure, we’ve a return to shareholders. In any other case, we are able to’t pay our taxes.”
Fortescue evaluation suggests renewable vitality options can compete instantly with different low emission energy sources, with working prices at $15-$45 per megawatt hour, evaluating favourably with LNG at $90-$100 per MWh and nuclear at $60-70 per MWh.
“The ability rail takes the normal advantage of trolley help, which is completed via overhead traces, however does it via a aspect mounted rail”
Trying ahead
This partnership represents greater than a single giant tools order – it demonstrates the technical and financial viability of large-scale mining electrification. With each firms dedicated to creating their zero-emission ecosystem accessible to the broader business, this collaboration has the potential to catalyze wider adoption of electrification applied sciences throughout the mining sector.
The validation timeline via 2026 will present essential real-world information on the efficiency of those built-in methods beneath precise mining situations. Success might set up the template for industrywide transformation, positioning this partnership as the muse for a basically completely different strategy to mining operations.
