Mining Fleet Electrification: 1,610 kW Charging Hub for Heavy-Duty Operations
Mining operations present some of the most demanding conditions for EV charging infrastructure. Dust, vibration, extreme temperatures, and 24/7 operational schedules require equipment that goes far beyond standard commercial specifications. This case study examines how FBK POWER designed and deployed a 1,610 kW charging hub for a major mining operation transitioning from diesel to electric heavy-duty trucks.
The Challenge: Electrifying a Mining Fleet
The client operates a open-pit iron ore mine with:
- 45 heavy-duty haul trucks (each requiring 300-500 kWh per shift)
- 3-shift operations (20 hours of active mining daily)
- Remote location (200km from nearest city, limited grid capacity)
- Harsh environment (dust, -20°C to +45°C temperature range)
Solution Design
Charging Hub Architecture
FBK POWER designed a centralized charging depot with modular expansion capability:
| System Component | Specification | Quantity |
|---|---|---|
| Split-Type DC Cabinet | 480 kW, 200-1000V | 3 units |
| Power Modules | 40 kW hot-swappable | 36 modules |
| Charging Connectors | CCS2 + custom mining connector | 12 ports |
| Battery Buffer System | 2 MWh BESS | 1 unit |
| Solar Canopy | 500 kW PV array | 1 installation |
Total Combined Capacity: 1,610 kW
Environmental Hardening
Standard EV chargers cannot survive mining environments. FBK POWER implemented:
- IP65 enclosure rating (vs. standard IP54)
- Active dust filtration with automatic purge cycles
- Liquid cooling for power modules in high-temperature conditions
- Vibration isolation mounts rated for mining equipment zones
- Heated cable management to prevent freezing in winter operations
Grid and Energy Strategy
The remote location meant grid power was insufficient for peak charging demand. FBK POWER's solution integrated:
- Battery Energy Storage System (BESS) — 2 MWh capacity absorbs peak demand, charges during low-cost periods
- Solar Canopy — 500 kW PV array over parking area reduces grid dependency by 25%
- Smart Load Management — AI-driven scheduling optimizes charging around mining shifts
Operational Results (First 6 Months)
| Metric | Target | Actual |
|---|---|---|
| Fleet Uptime | 85% | 91% |
| Charger Availability | 95% | 98.2% |
| Energy Cost per km | $0.45 (diesel baseline) | $0.28 |
| CO2 Reduction | 30% | 42% |
| Maintenance Downtime | <5% | 2.1% |
Key Insights for Heavy-Duty Fleet Charging
- Oversize power capacity by 50% — mining fleets grow faster than projected
- Invest in BESS early — it pays for itself within 18 months through demand charge reduction
- Design for maintenance access — cramped installations triple service time
- Train local technicians — remote mines cannot wait for factory support
ROI Analysis
| Cost Category | Diesel (Annual) | Electric (Annual) | Savings |
|---|---|---|---|
| Fuel/Energy | $4.2M | $1.8M | $2.4M |
| Maintenance | $1.1M | $0.6M | $0.5M |
| Carbon Credits | $0 | $0.3M | $0.3M |
| Total | $5.3M | $2.7M | $2.6M (49%) |
Payback period for charging infrastructure: 3.2 years
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Interested in heavy-duty fleet electrification? [Download our fleet charging whitepaper](/quote) or [schedule a consultation](/contact).
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