Hydrogen in the Mining Industry
Connor Dolan
By Nova Thayer
The materials mining industry is essential for the modern economy and is also responsible for approximately 4% to 7% of total global carbon emissions released into the atmosphere. Large machines and remote exploration sites are often dependent on loud, inefficient diesel or other fossil fuel-powered generators. The status quo can’t be maintained in the face of climate change and limited resources, and mining companies are investigating alternatives that will produce less carbon and allow operations to continue unhindered. Ultimately, hydrogen is coming to the top of the list because of its reliability, large energy storage potential, and synergy with renewable energy.
Hydrogen has several advantages that other energy sources do not. Renewable energy is often abundant during specific hours, but solar and wind generation are intermittent over longer periods of time. Mining is also heavily dependent on very energy intensive machines, and electrical batteries often don’t have the necessary energy density to run large mining drills or large trucks, have weight limitations, and take longer to recharge than incumbent fossil fuel equipment.
Hydrogen offers a solution to these problems, with a high energy density, quick refueling times, and consistent power supply that keeps powerful machines running without delay. Hydrogen fuel cells are very versatile, and can be sized to power drills, large haul trucks, small hauling carts, lifts, generators, and mineral processing machines. Hydrogen used in a fuel cell produces only water as a byproduct, providing a significant environmental benefit over diesel generators and engines.
A basic overview of the possible uses for hydrogen in the mining industry. (Source: ENGIE)
As costs continue to fall for fuel and technologies, and as demand for emission-free machines continue to rise, it seems the hydrogen involvement in mining sites will continue to rise as well. Clean power with no loss in productivity is a high priority across the industry. Below are several companies that are investing in hydrogen and fuel cells to reduce emissions at work sites and encourage the use of hydrogen across the industry.
Anglo American, ENGIE, Plug Power, And Ballard
In South Africa, FCHEA members Anglo American, ENGIE, Plug Power, and Ballard Power Systems have been collaborating to produce a hydrogen-powered mining haul truck. The partners recently unveiled their proof-of-concept vehicle, the nuGen™ Zero Emission Haulage Solution, and the fuel cell hauler is active at Anglo American’s Mogalakwena Platinum mine. With a payload of 290 tons, the truck is currently the world’s largest heavy-duty hydrogen vehicle. The hauler is supported with a solar-powered electrolyzer which produces clean hydrogen on site and is powered by Ballard’s fuel cell modules. The three companies plan to expand production of the hauler model across the Mogalakwena mine first, and ultimately to the rest of Anglo American’s mining operations worldwide. This will help Anglo American to completely decarbonize the mine operations, and the company’s combo of electrolyzers on site with hydrogen powered machines is likely to catch on in other mining sites. Click here to see a video describing the development process and showcasing the haul truck in action.
A photo of the completed hauler. The truck is being launched first at Anglo American’s Mogalakwena mine in South Africa. (Source: Anglo American)
Cummins
Another FCHEA member, Cummins, is working on prototyping hydrogen-powered ultra-heavy duty mining trucks, in partnership with construction and mining manufacturer Komatsu. The companies announced that they would work on developing a fuel cell power source compatible with Komatsu’s power agnostic truck concept architecture.
Hydra Consortium
In Chile, Mining3, an Australian mining company, is partnering with FCHEA members ENGIE, Ballard, and Hexagon Purus to create the Hydra Consortium. The group is working with the Chilean government via a grant program to create a hydrogen fuel-cell-based heavy-duty powertrain. The companies plan to scale up the demonstration in 2023, seeking to convert a mining hauler to run on hydrogen. The companies then plan to shift the entire fleet at the Antofagasta copper mine by 2025, utilizing an onsite solar powered electrolyzer to supply the hydrogen.
Conclusion
The mining industry, with its focus on extracting the necessary minerals and fuels that power the modern economy, is the perfect example of a hard-to-decarbonize sector. The machinery is huge, energy-intensive, and switching to electric battery systems can hurt productivity by increasing charging time. Thankfully, hydrogen is the solution that mining companies have been looking for. By utilizing hydrogen, companies can keep the heavy machinery online and productive, so it seems likely that more hydrogen-powered machines and mines will appear in the future, reducing carbon emissions in local mine environments and across the planet.