Mining – Electrification and System Integration
Mining and electric mobility are closely interconnected. Mined raw materials such as lithium, nickel, cobalt, graphite, copper, and aluminum make electric mobility possible in the first place. Now mine operators themselves are under pressure to reduce emissions while simultaneously increasing efficiency and safety. We support operators and OEMs in implementing electric mining systems.
Practical Requirements
Challenges
High Emission Pressure and Regulatory Requirements
The mining sector plays a central role in the energy transition and must significantly reduce its emissions by 2050. Pressure from investors and customers is increasing to implement ESG-compliant solutions.
Complex Energy and Infrastructure Requirements
Many mines are located in remote regions with limited access to stable power grids. Electrification requires high-performance energy supply, charging infrastructure, and in some cases dedicated microgrids.
High Energy Demand and Cost Structure
Energy consumption is one of the largest cost blocks in mining. Diesel prices are high and volatile. Electrification can reduce energy costs, although infrastructure requirements increase.
Technological Limits in Heavy-Duty Applications
Particularly for large transport vehicles, battery density, charging times, and system integration are central challenges. Different technologies such as BEV, trolley operation, or hydrogen solutions must be evaluated depending on the application.
Complex System Integration
Mining is a highly integrated system. Vehicles, energy supply, charging infrastructure, thermodynamics, and digital systems must work together seamlessly. Standard solutions are rarely sufficient for mining operators.
Are these your challenges as well? We would be happy to develop the right solution for you.
At a glance
Facts & Figures
Required Emission Reduction in the Mining Sector by 2050
Possible CO₂ Reduction Through Complete Electrification
Potential for Reducing Energy Costs Through Electrification
How Much Maintenance Costs Can Decrease for Electric Machines
Lower TCO for Electric Vehicles in Certain Applications
Share of Energy Costs in Total Operating Costs in Mining
Share of Ventilation in Energy Costs in Underground Mining (with Diesel Operation)
Typical Application Range in Which Battery-Electric Vehicles Are Economically Viable Today
5 Reasons for SUNCAR
Why SUNCAR for Mining
Mining electrification is not a component problem, but a system challenge. This is where we come in.
Understanding of Complex Mining Systems
Mining machines are not a standalone product, but an integrated system of vehicles, energy, and infrastructure. We develop solutions that account for this complexity.
System Integration Instead of Isolated Solutions
Electrification requires the interaction of drive, energy supply, charging infrastructure, and software – this is precisely where our strength lies.
Focus on Real Operating Conditions
Our solutions are designed for extreme load profiles, long operating hours, and demanding environments.
Efficiency and Operating Costs in Focus
Electrification offers potential for reducing energy and maintenance costs. We develop systems that realize this economic benefit.
Integration of Electrification and Digitalization
Data, monitoring, and intelligent systems are central components of modern mining operations and are considered from the outset.
Convinced? Then please get in touch with us. We look forward to supporting you with your project.
Turning Complexity into a System
Mining: Our Solution Competence
The market is evolving: electrification in mining is gaining traction where energy supply, application profile, and economic benefit align. At the same time, the transformation is not happening in isolation, but together with digitalization, automation, and new energy systems.
We do not only develop electric subsystems, but view mining operations as an integrated system. This includes electric drives, high-voltage and low-voltage architectures, energy distribution, charging infrastructure, thermal management, as well as control and monitoring solutions.
A key lever lies in the integration of energy and operating systems. Electrification not only enables the replacement of diesel, but also opens up new potential for more efficient operations, reduced downtime, and optimized energy flows.
Success Stories
Reference Projects
Successful electrification projects from various industries
Tailor-made Solutions
Relevant Products and Technologies
High-voltage distribution systems
For electric mining applications, robust and scalable HV architectures are critical to safely distribute and control large amounts of energy.
Control Software and System Logic
Complex mining applications require coordinated control of drive, energy, charging processes, and operating states.
Our Approach
Our Process
From application analysis to validated solution – we develop mining systems systematically and with a focus on the demanding requirements of real-world operations.
Analyze Application Profile
We analyze machines, operating conditions, energy requirements, and infrastructure.
Define System Architecture
We develop the architecture for drive, energy, HV/LV systems, thermodynamics, and charging infrastructure.
Implement Integration
The systems are integrated mechanically, electrically, and in terms of software.
Validate and Optimize
The solution is tested in real-world operation and continuously improved based on operating data.