Hydrogen has emerged as a potential solution to one of mining’s most difficult decarbonisation challenges: heavy mobile equipment. Where battery-electric solutions face weight and charging constraints, hydrogen offers an alternative pathway. Progress is real, but significant challenges remain.

The Case for Hydrogen in Mining

Mining’s largest mobile equipment presents particular challenges for electrification. A 400-tonne haul truck consuming megawatts of power during operation needs either enormous batteries or frequent, lengthy charging. Neither option integrates easily with mining operations optimised for continuous productivity.

Hydrogen potentially solves this problem. Fuel cell systems convert hydrogen to electricity with only water as exhaust. Refueling takes minutes rather than hours. Energy density supports the demands of heavy equipment.

The environmental case is compelling when hydrogen is produced from renewable electricity. Green hydrogen enables zero-emission operation of equipment that diesel would otherwise power for decades.

Miners are also evaluating hydrogen because customers and investors increasingly expect decarbonisation commitments. Pathway to zero emissions for haul fleets demonstrates credibility of these commitments.

Current Development Status

Several equipment manufacturers and mining companies have hydrogen equipment programmes underway.

Haul truck trials are being conducted by multiple parties. Anglo American’s nuGen hydrogen-powered haul truck has completed testing at Mogalakwena in South Africa. Fortescue has tested hydrogen fuel cell systems in haul trucks at its Australian operations.

Underground equipment hydrogen applications are being developed. The confined environment of underground mines, where battery charging infrastructure is challenging and diesel emissions are problematic, may be well-suited for hydrogen.

Auxiliary equipment trials are advancing. Hydrogen fuel cells for light vehicles, drill rigs, and other equipment face fewer technical challenges than large haul trucks.

Hydrogen production facilities at mine sites are being planned and in some cases constructed. On-site electrolysis powered by renewable energy produces green hydrogen without transport costs.

The technology is proven at demonstration scale. The challenge is progressing to commercial-scale deployment that works economically and operationally.

Technical Challenges

Several technical challenges must be addressed for hydrogen to achieve widespread mining adoption.

Storage and handling of hydrogen requires careful engineering. Hydrogen’s low density means large storage volumes or high pressures. Cryogenic liquid hydrogen offers higher density but adds complexity.

Refueling infrastructure must be developed at mining operations. Unlike diesel infrastructure that has evolved over decades, hydrogen systems are new to most mines.

Fuel cell durability in mining conditions needs validation. Dust, vibration, and temperature extremes challenge components designed for gentler applications.

Power density requirements for large equipment push fuel cell system designs. Haul trucks need peak power levels that require substantial fuel cell stacks.

Maintenance capability for fuel cell systems must be developed. Workforce skills and parts inventory differ significantly from diesel equipment.

Economic Considerations

Hydrogen economics remain challenging compared to diesel, though the comparison is evolving.

Hydrogen production costs have declined significantly but remain above diesel energy equivalent in most circumstances. Green hydrogen is more expensive than grey hydrogen from natural gas.

Equipment costs for hydrogen systems exceed diesel equivalents due to low production volumes and developing technology. Costs will decline with scale, but current premiums are substantial.

Infrastructure investment adds to total cost of conversion. Hydrogen production, storage, and dispensing facilities require significant capital.

Operating costs may favour hydrogen in some analyses. Fuel cells have fewer moving parts than diesel engines, potentially reducing maintenance costs.

Carbon pricing and other policy mechanisms improve hydrogen economics. As carbon costs rise, the comparison with diesel shifts.

The current economic case for hydrogen typically requires either policy support, premium pricing for low-carbon products, or strategic positioning for future regulatory requirements.

Industry Collaboration

The scale of investment required for hydrogen in mining is driving collaboration among stakeholders according to industry analysis from the International Energy Agency.

Mining company consortia are forming to share development costs and risks. No single mining company can drive equipment manufacturer investment alone.

Equipment manufacturer partnerships combine capabilities across the hydrogen value chain. Truck manufacturers partner with fuel cell specialists and hydrogen infrastructure providers.

Government support through funding and policy provides incentive for early deployment. Several mining jurisdictions offer programmes supporting hydrogen trials.

Research collaborations advance fundamental technology applicable across multiple applications. Mining-specific research builds on broader hydrogen technology development.

The Path Ahead

Hydrogen will likely play a role in mining’s energy transition, though the extent and timing remain uncertain.

The next few years will see expanded trials and initial commercial deployments. Learning from these projects will inform broader adoption decisions.

Battery-electric and hydrogen solutions will likely coexist, with suitability depending on application characteristics. Shorter hauls and smaller equipment may favour batteries; longer hauls and larger equipment may favour hydrogen.

Mining companies should monitor hydrogen developments and evaluate opportunities for trials. The learning opportunity from early adoption may be valuable even if economics are not yet compelling.

The transition to zero-emission mining equipment will take decades. Hydrogen appears likely to be part of that transition for applications where batteries face fundamental constraints.