Electric Power Conversion Australia (EPCA), a pioneering Perth-based company, is making waves in the mining industry with its ambitious electrification projects. EPCA recently unveiled its latest innovation: a fully retrofitted CAT 777 haul truck, now powered entirely by batteries. This retrofit represents a significant technological advancement and a major step towards greener mining operations in Western Australia.
The CAT 777, a 100-ton payload truck, is one of the most commonly used models across various mining operations in Western Australia. By converting this diesel-powered workhorse to electric, EPCA addresses a critical need to reduce carbon emissions in a sector where mobile machinery, especially trucks, accounts for up to 50% of total emissions. The retrofitted CAT 777, now dubbed the “Green Machine,” boasts a power output increase from 746 kW to 824 kW and a torque jump from 4,700 Nm to 5,200 Nm. These improvements are made possible by integrating six batteries, delivering a total of 1,741.8 kWh, which EPCA proudly claims gives the truck “the world’s highest energy density.”
EPCA’s innovation doesn’t stop at power and efficiency. The “Green Machine” offers a suite of benefits for mining operators, including reduced noise and vibration, enhanced safety, and increased comfort for operators. The truck can operate for 8 hours on a full battery charge and can be recharged in just 50 minutes, making it highly suitable for continuous mining operations.
The industry has responded enthusiastically to EPCA’s retrofit, with considerable interest in the 100-ton electric truck, especially given its potential to cut operational and maintenance costs significantly. Typical diesel cost for a 777 is $102/hr whereas for electric it is $22/hr (assumes 6000hrs per year, diesel $1.60/L and electricity cost $135/MWhr). Maintenance cost are typically $104/hr which are reduced to $62/hr for electric.
Performance testing for the truck is near completion at a mine site north of Perth. The BET moves 100t up a 12% incline with ease. The truck can completely stop on the incline (fully loaded) and then accelerates away. The truck runs for over 8 hours and nearly 1000tonnes of material has been moved.
Endurance testing for EPCA’s retrofitted battery-electric mining trucks will be conducted across a diverse range of mine sites in Western Australia. These sites are strategically selected to represent a wide array of operating conditions, including the hot and dry heat of the Pilbara, the wet and humid Southwest, and the desert of the Goldfields.
The data collected from these tests will be integral to optimising truck performance. EPCA has developed a sophisticated client dashboard that provides detailed data analytics, allowing clients to monitor the trucks’ performance and endurance in real time. This level of insight ensures that any issues can be quickly identified and addressed, further improving the reliability and efficiency of the electric trucks.
To expand its global reach, EPCA has established a strategic partnership with a multinational company that has workshops worldwide and a global reach. This collaboration guarantees that overseas clients can access EPCA’s retrofitting services, converting their diesel-powered mining trucks to more sustainable battery-electric models.
Once endurance testing is completed, full-scale production of the retrofitted trucks will commence simultaneously at multiple workshops across the globe. This worldwide production capacity, supported by EPCA’s distribution network, positions the company to efficiently fulfil its growing order book. By utilising this extensive network, EPCA is set to revolutionise the mining industry with its innovative battery-electric solutions, providing a sustainable and efficient alternative to traditional diesel-powered mining equipment.
