In a landmark move for Pakistan’s mining industry, Sindh Engro Coal Mining Company (SECMC) has become the first mining company in the country to transition to electric vehicles (EVs). This bold initiative marks a significant step towards lowering operational costs, and setting a new standard for sustainable mining practices in the region. By integrating EV trucks into its fleet, SECMC says it continues its stance positioning itself as a pioneer in innovation within the mining sector in the country.
SECMC is Pakistan’s leading coal producer, operating the country’s first open-pit lignite mine in Block II of Tharparkar area in Sindh province of Pakistan. One of the first public-private partnership companies in Pakistan, it has a current annual mining capacity of ~7.6 Mt and is working to enhance capacity to 12 Mt/y with 70 MBCM of overburden removal. The indigenous lignite resource is one of the cheapest baseload fuels available in the country to provide affordable electricity to the consumers, the industry and the country at large.
According to Arsalan Anwar, Manager Mine Technical & Expansion at SECMC, the mining industry has long been reliant on diesel-powered machinery, which accounts for a significant portion of cost. He states: “Currently, SECMC is operating around 250 diesel dump trucks for haulage of 4 MBCM of overburden monthly. Diesel trucks are not only expensive to operate but also harmful to the environment. The mega-shift to EVs is simply logical and a necessary step forward.”
He emphasised that SECMC’s initiative is part of a larger global trend. “Around the world, mining giants like BHP and Rio Tinto are already trailing electric trucks,” he said. In China, manufacturers are producing thousands of electric mining trucks. In this regard, a delegation of SECMC visited several other mines globally and analysed the technical data of their EV trucks to assess the fast efficiency. The outcome seemed viable which compelled the mining company to incorporate EV trucks in to its haulage fleet. Therefore, four EV trucks of 70 tons capacity were procured and are being tested on different environmental conditions. There are two pairs of battery electric trucks from two Chinese OEMs – two TLE105 trucks from TONLY and two YTE105E trucks from YUTONG.
On downhill loaded conditions slopes ranging from 6% to 8%, the truck requires charging every 1 to 2 days. Operating heavy-loaded EV mining dump trucks on downhill gradients saves significant energy. The energy associated with heavy-loaded downhill operations is saved by over 90%. However, for deeper mines with uphill loaded conditions gradients exceeding 5%, frequent battery charging is necessary, requiring multiple exchanges throughout the day to maintain optimal performance. This would add into downtimes and production delays. Some companies are integrating the trolley system with EVs to cope up with this challenge while others are working with battery swapping.
The transition to EVs isn’t without its challenges. Anwar pointed out several hurdles that SECMC and other mining companies might face. “Charging infrastructure is a big challenge,” he said. “Mining sites are often remote, and setting up reliable charging stations can be a logistical challenge. Battery performance is another concern, especially in extreme weather conditions like the +50°C temperatures SECMC operates in.”
Battery technology, particularly energy density, which currently may not support the long-distance, heavy-duty demands of mining. Charging time and battery life can impact operational efficiency. However, ongoing advancements in battery technology such as setting up Megawatt Charging Stations (MCS) can reduce the charging time. Typically, a 400 KWh battery is charged in 90 mins, however with an introduction of new technology the charging time is reduced to 12 KWh/min.
There is also a higher initial cost of electric trucks, driven by expensive batteries and the necessary charging infrastructure. Although upfront costs are higher, long-term savings in fuel and maintenance, as well as government incentives, can offset this investment. Furthermore, advancement in battery technologies has resulted in reduction of battery cost.
The increased demand for electricity to charge a fleet of EV trucks can strain the local power grid, potentially leading to instability and outages. Integrating renewable energy sources, such as solar or wind power, with energy storage systems can help stabilise the grid. On-site renewable energy generation can reduce reliance on the grid and provide a sustainable power source for charging EVs.
Weather conditions also affect battery performance, with cold temperatures reducing capacity and high heat causing overheating. Advances in battery thermal management and weatherproofing will help address these issues.
Anwar also highlighted the economic benefits of this transition. “The upfront costs of EVs are high, while the long-term savings in fuel and maintenance are substantial,” Anwar said. “SECMC’s trial of four EV trucks is a smart move to assess their performance in local conditions before scaling up.”
Electric vehicles (EVs) requires 100% more CAPEX as compared to diesel trucks, Anwar said. This includes the cost of purchasing electric mining trucks, installing charging infrastructure, setting up battery swapping/charging stations. On the other hand, EV trucks have fewer moving parts, which needs less maintenance requirements and less frequent breakdowns. This will result in lower repair and maintenance costs, contributing to 20-30% reduced OPEX over the life of the vehicle with a payback period of four to five years. “By integrating EV trucks into our fleet, we can improve the availability of our trucks, ensuring smoother and more efficient mining operations.”
“The power tariff plays a crucial role in the economics of EVs,” he added. With reduction in renewable tariffs and recent developments in BESS (Battery Energy Storage System) technologies the EVs can be competitive against diesel trucks. Furthermore, there could be savings up to 30-40% in terms of fuel consumption if site conditions are suitable for EVs.
“A typical diesel truck consumes 0.8-1.2 litres per BCM of waste and a single diesel truck emits 2.6 kg of CO2 per litre of fuel. By switching to EVs, SECMC can drastically reduce its carbon footprint. This isn’t just good for the environment but also good for business. Lower fuel and maintenance costs mean significant savings over time.”
Anwar also highlighted the importance of aligning with global sustainability goals. “The world is moving towards a greener future, and industries that don’t adapt risk being left behind. SECMC’s initiative positions them as a leader in sustainable mining, which can attract environmentally conscious investors and partners.”
Anwar concludes: “This isn’t just about reducing emissions or cutting costs. It’s about reimagining what the mining industry can be in a place like Pakistan. The road ahead is electric, and the possibilities are endless.”
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