Tag Archives: mine electrification

CEEC’s latest workshop to examine new gen energy options for miners

Comminution of minerals, Energy minerals, Environmental, Mineral processing, Mining equipment, Mining events, Mining services, Mining techniques, Power supply for mines, Sustainable mining, , , , , , , , , , , , , , , ,

With more and more mining sector interest in energy efficiency and uptake of renewables, the global not-for-profit communication hub for energy efficient mineral processing, CEEC, says it is running a series of workshops to share the latest developments in this field.

The next one-day Mineral Processing and Innovation Workshop on Energy Curves, Productivity and New Gen Energy, will be held at the National Wine Centre in Adelaide on June 19.

This event is due to kick off with a keynote address from OZ Minerals CEO and MD, Andrew Cole, who will share his vision for steering smart energy and productivity for sustainable mining, processing and communities.

Marc Allen, CEEC Director and Technical Director at engeco, said there was a worldwide trend towards new-generation energy options such as solar, battery-electric power and hydrogen – not only in the sector but for global power generation to combat climate change.

“The paradox is that these low carbon technologies are minerals intensive, and metals such as copper, nickel, lithium and cobalt will be required in greater volumes to make this transition possible,” Allen said.

“The shift towards a decarbonised energy future has significant ramifications for the global mining industry, particularly given the energy intensive nature of comminution and mining, coupled with the remoteness of most mineral deposits.”

Allen said renewable energy sources with low carbon energy backup options and/or energy storage were becoming more and more common in mines, with one leading example being the solar project at Degrussa Copper-Gold Mine in Western Australia.

Sandfire Resources’ Degrussa Solar project, commissioned in 2016, is reported to be the world’s largest integrated off-grid solar and battery storage facility. It supplies about 20% of the mine’s annual power requirements and has reduced emissions by close to 12,000 t/y of carbon dioxide, according to CEEC.

“South Australia is also leading the way with adopting new-gen energy. BHP is trialling zero-emission light electric vehicles at its Olympic Dam mine and has plans to progressively replace diesel fuel with lithium-ion batteries,” Allen said.

Canada’s first all-electric mine (Borden) is also on the cards, being constructed by CEEC sponsors Newmont-Goldcorp, Sandvik and MacLean Engineering.

Allen said: “Newmont-Goldcorp’s target is to increase energy efficiency by 15% over five years and source 5% of its energy from renewables. It’s pleasing to see that other major mining companies are fast following suit, introducing bold targets to shrink their carbon and energy footprint.”

Another standout country is Chile, with reports of nine companies, including copper miners Codelco and Antofagasta Minerals, introducing renewable energy such as wind and solar power.

In addition to transitioning to clean energy technologies, mining operations are striving to improve the energy efficiency of comminution. In Australia, alone, copper and gold mines’ comminution processes consume 1.3% of national electricity production, as well as being key constraints to site productivity, value and mining footprint.

Speakers and panellists at the CEEC Mineral Processing and Innovation Workshop in Adelaide on June 19 will share the latest technologies and methodologies being employed to boost energy efficiency, value and productivity in processing plants and mine sites, according to CEEC.

Keynote speaker Cole will be joined by leading mining, METS and research experts from across Australia, including Energy Curve researcher Dr Cathy Evans, Senior Research Fellow, University of Queensland Sustainable Minerals Institute; Professor Stephen Grano, Executive Director, Institute for Mineral and Energy Resources, University of Adelaide; and Professor Bill Skinner, Research Leader, Future Industries Institute, University of South Australia.

With data science and AI also being key drivers for improving operational efficiency and dispatch of electrical energy, workshop participants will hear from PETRA Data Science’s Managing Director, Dr Penny Stewart, and Technical Director, Dr Zeljka Pokrajcic.

Innovative METS leaders, including Greg Lane, Ausenco; Sandy Gray, Gekko Systems; and Bear Rock Solutions’ Dr Ted Bearman and Adjunct Professor Rob Dunne, will present practical advances in comminution technology.

Insights into South Australia mining and mineral processing innovations will be provided by Joe Seppelt, OZ Minerals Processing Manager at the Carrapateena copper-gold project, north of Port Augusta, and Enzo Artone, BHP Area Manager, Mill and Process Minerals, BFX Project, Olympic Dam.

To register or find out more about the workshop, which will be held at the National Wine Centre, click here.

Epiroc books battery-electric equipment order from Canada underground mine

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Epiroc received a large order for its battery-electric underground equipment from Canada in the March quarter, the company confirmed in its latest quarterly results.

The company, in November, launched its second-generation battery-electric solutions in Örebro, Sweden, presenting 14 t and 18 t LHDs, a 42 t truck (MT42) and its mid-sized drilling family including face drilling, production drilling and rock reinforcement rigs.

In the March quarter results, the company did not mention the name of the miner, the site the equipment will be deployed at, or which machines will be used at the operation, but, at a Bauma media roundtable event, President and CEO, Per Lindberg, said of the recent second generation launch: “We can say that the reception has not been worse than expected. It has been better than expected, and we have high expectations.”

And, earlier this month at The Electric Mine conference, in Toronto, Canada, Morgan Rody, Senior Project Manager: Sustainable Intelligent Mining Systems (SIMS), Global Strategic Projects and Alliances, Epiroc, said one of Epiroc’s second-generation battery-electric drill rigs was set to arrive at Agnico Eagle’s Kittilä gold mine, in Finland, in a matter of weeks as part of the SIMS project.

Going back to the mining equipment manufacturer’s Q1 results, the company said orders received came in at SEK 10.06 billion ($1.06 billion) during the quarter, a year-on-year organic decline of 5%, while both revenues and operating profit rose – 19% to SEK 9.79 billion for the former and 27% to SEK 1.93 billion for the latter.

The company’s operating margin went from 18.4% a year earlier to 19.7%, while its basic earnings per share jumped from SEK 0.89/share to SEK 1.14/share.

Lindberg said, during the quarter, the company’s service business continued to grow “healthily”, having a positive impact on the group’s overall profit.

“Equipment revenues increased versus last year, but fell sequentially compared to the very strong Q4, which had a negative effect on our cost efficiency in the quarter,” he said.

“In the Tools & Attachments segment, we are pleased to see that our efficiency actions had a positive effect on the operating profit and margin. Working capital increased in the quarter, and continues to be a focus area for improvement. The operating cash flow was lower than in the previous quarter as a result.”

He said customer demand in the March quarter was “largely in line with our expectations”, with equipment orders at similar levels to the second half of 2018.

“The majority of mining equipment orders are still for expansion in or close to existing mines rather than for replacement,” he said. “The aftermarket business remained strong, reflecting the solid activity in the market, both in mining and in infrastructure.

“While our customers continue to be active and relatively confident about the future, and the mineral prices are at healthy levels, there are still uncertainties related to the economic development.

“We see that our customers primarily invest in lower-risk projects with focus on increased productivity and efficiency. We do not see any clear indications that the current market situation will change and expect that the demand will remain at the current level in the near term.”

During the quarter, the company completed its earlier announced acquisitions of Fordia and New Concept Mining, strengthening its position in exploration and rock reinforcement, and adding some SEK 1.2 billion in annual revenues, according to Lindberg.

On innovations, automation, digitalisation and battery power, Lindberg remarked: “We are pleased to see that we received several inquiries and orders for automation and battery solutions.”

On top of the battery equipment order from Canada, he said orders were booked for Mobilaris Mining Intelligence and, at the Bauma exhibition in early April, the company had presented a number of innovations, including My Epiroc, “a digital tool to help our customers to become more efficient in managing their fleet”, and its new generation SmartROC D65, an automation-ready surface drill rig.

Lindberg concluded: “In 2018, we put a lot of effort into the split and listing of Epiroc. In 2019, we will focus on improving and developing the business further. Besides the continued emphasis on innovation and new product development, a key focus will be on improving efficiency, agility and resilience throughout the company.”

Codelco puts its mine electrification efforts into first gear

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Codelco says it will trial a Komatsu hybrid LHD at its El Teniente underground copper mine, in Chile, as the company looks to reduce the amount of greenhouse gas it emits from its operations.

The diesel-electric hybrid is likely to increase productivity by 10-20% and cut diesel consumption by at least 25%, Codelco said.

The LHD is just one of a number of pieces of new equipment the company is bringing into the El Teniente operation to reduce its carbon footprint. The others include an RDH-Scharf electric scissor lift (the Liftmaster 600 EB), which comes with operating costs 70% lower than the diesel equivalent; two 100%-electric buses to transport workers from Rancagua to the El Teniente operations (at 3,100 m high); and a 100%-electric bus link for urban use within Rancagua.

“Codelco’s electromobility strategy also contemplates the incorporation of an electric bus for the Chuquicamanta Division for the first half of this year,” Codelco said in a statement translated from Spanish to English. “In addition, El Teniente will add three additional electric buses during the year, a second LHD, this time 100% electric, and an electric mining truck for the interior of the mine.”

Octavio Araneda, a Vice President of Operations for Codelco, said (also in Spanish to English translation): “In the framework of our Sustainability Master Plan, in Codelco we execute a transition program to gradually decarbonise the energy matrix of our operations.

“An edge of this initiative is our strategy of electromobility that, after positively avoiding a pilot experience with light vehicles last year, today celebrates this new milestone with unprecedented production teams. ”

On the Komatsu hybrid LHD, Codelco said the electric drive machine has no gearbox or filters and uses diesel only for the generation of “motive power”.

“It will be used industrially for the first time in Codelco El Teniente to start marketing it to the rest of the industry internationally,” Codelco said.

Komatsu has, so far, released details on an 18 t hybrid LHD (the Joy 18HD) and a 22 t hybrid model (Joy 22HD). Last year, Byrnecut Australia said it was to trial a Joy 22HD at OZ Minerals’ Prominent Hill copper-gold mine in Australia in the June quarter of 2018, as it looked to test production efficiencies, diesel savings and overall costs associated with this equipment.

Codelco is hoping use of this hybrid LHD will bring down operating costs by 30%, increase the reliability and availability of LHDs by 10-20% – due to less engine hours, longer life and easier replacement of components – and reduce emissions and heat released by over 25%.

The company is after an even bigger boost in scissor lift use, expecting reliability and availability of the new machine to go up 20-30%, while the energy expenditure of the electric scissor platform is expected to be just 75-149 kW. Noise reduction is estimated at 70% compared with the diesel version, while the heat released is expected to drop 80-90% when compared with the diesel version.

The XMQ6130 eTech electric buses transferring workers from Rancagua to El Teniente have been manufactured by King Long in China and can hold 44 passengers, while the urban electric buses, also built by King Long, are the model XMQ6127e for up to 87 passengers.

Agnico Eagle’s Kittilä readies for Epiroc second-gen battery-electric machines

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One of Epiroc’s second-generation battery-electric drill rigs is set to arrive at Agnico Eagle’s Kittilä gold mine in Finland in a matter of weeks, attendees at The Electric Mine conference in Toronto, Canada, heard on Friday.

According to Morgan Rody, Senior Project Manager: Sustainable Intelligent Mining Systems (SIMS), Global Strategic Projects and Alliances, Epiroc, the mine is due to receive the rig as part of the EU-backed SIMS research initiative.

SIMS is a three-year Horizon 2020-funded European-wide project aimed at demonstrating that the European mining industry and technology providers are global leaders with such sustainable and intelligent mining systems. Horizon 2020, meanwhile, is the biggest EU Research and Innovation programme ever.

The Epiroc battery-electric drill rig is scheduled to be followed over the next few months by the arrival of a second-generation Epiroc MT42 haul truck and a second generation LHD, he added.

Epiroc officially launched the second generation of its battery-electric vehicles at an event in Örebro, Sweden, last year. This came after its first-generation machines had clocked up over 60,000 hours of operations.

 

Andrew Schinkel on Kirkland Lake Gold’s battery-electric journey at Macassa

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Kirkland Lake Gold is now carrying out more than 80% of its ore production from the Macassa gold mine in Ontario, Canada, with battery-electric machines, Andrew Schinkel, Senior Electrical Engineer, Macassa Mine Complex, told attendees at The Electric Mine conference in Toronto on Thursday.

The company placed its first battery-electric machine order in 2011, but now has 24 battery-powered LHDs and nine haul trucks (including four 40 t Artisan Vehicles Z40 machines, and Epiroc and RDH Scharf LHDs, among other machines), Schinkel said in a presentation titled, Powering up Macassa: operating a major battery-electric fleet at a deep underground mine.

The company’s learnings over the past eight years have been vast, but the main points Schinkel highlighted were trucks had slightly more availability than loaders, batteries can run down power quickly, the capital cost can be slightly higher than the diesel equivalent – but “it’s not about minimising costs, it’s about maximising value”, he said – and there is not as much equipment to choose from when compared with diesel machines.

Still, the company has made significant progress with these machines, he said. This includes increased reliability of machines, an increasing amount of purchasing options and improvements in the battery change-out process.

Boliden and Vattenfall sign agreement to electrify mines and smelters

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Vattenfall and Boliden say they have signed an agreement to jointly evaluate technical developments to electrify mines and smelters, “the circular economy and a fossil-free future”. The agreement, which covers a four-year period, also includes battery solutions with a view to supporting the electricity grid and optimising electricity consumption, the two companies said.

The companies said: “Vattenfall and Boliden are committed to the transition to a sustainable society, which means reducing dependence on fossil fuels. Under the new four-year strategic agreement, the companies will develop business solutions involving batteries, solar panels, electric transport and recycling of new generation car batteries.”

President and CEO of Vattenfall, Magnus Hall, said: “It’s great that Vattenfall and Boliden can work together on this. It will require technological change and investments in new solutions, but the opportunities are there for both companies. Industrial partnerships like this are crucial if we are to make progress on the electrification of industry and enable fossil-free living within one generation.”

President and CEO of Boliden, Mikael Staffas, said: “Boliden is one of Europe’s largest players in the field of base metals. These metals are a crucial part of the solution for achieving ambitious climate targets in society. At the same time, it’s clearly important for us to drive the development forward within the raw materials sector and identify business solutions and processes for both mining and recycling which will make us more competitive.”

Boliden has mining and smelting operations in Sweden, Finland, Norway and Ireland, with the main sources of fossil emissions include diesel vehicles, process heat and coke as a reducing agent.

“In all areas, fossil-free electricity can be an important part of the solution,” the two companies said. “As a technology-independent partner, Vattenfall can evaluate and enable the introduction of fossil-free technologies, eg electricity and charging infrastructure for transport and mining.”

As a first step in the partnership, modern energy solutions will be implemented at the Bergsöe lead smelter in Landskrona, one of Europe’s largest recyclers of lead batteries from cars. Solar panels, which will produce locally generated renewable electricity to power the plant, will also be installed shortly, according to the two companies.

Technical solutions involving batteries, among other things, are expected to reduce the load on the electricity grid, provide backup power, reduce peaks in capacity and offset renewable weather-dependent electricity generation, they said.

ABB looks to improve mining efficiency with ABB Ability™ MineOptimize

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ABB has launched its ABB Ability™ MineOptimize suite of digitally connected products, services and solutions to, the company says, “realise the world’s most efficient mines”.

“With digitalisation at its heart, ABB Ability MineOptimize connects all electrification, automation and digital offerings to optimise all stages in the lifecycle – from design and build to operation and service – of any open pit or underground mine and minerals processing plant,” ABB said.

MineOptimize is a portfolio of optimised electrification, drives and automation solutions, optimised engineering, digital applications and collaborative services, according to ABB. “It combines in-depth sector knowledge, leading edge technology and global and local project management, engineering and digital transformation expertise developed by ABB over 60 years of working with the mining and minerals industry at every stage of the mining cycle,” the company said.

The products, services and solutions within the solution include state-of-the-art digital technologies for remote services, predictive maintenance tools as well as solutions for upgrades and retrofits, according to ABB.

The company said: “Advanced application libraries, software solutions and digital platforms reduce process complexity, promote safe and secure production and lower lifetime operating costs. By ensuring that the right people have the right information at the right time and from anywhere, ABB Ability MineOptimize digital applications enable mine operators to maximise reliability, safety, productivity and energy efficiency while optimising planning and visibility across operations and the entire enterprise.”

Martin Knabenhans, Head of Product Management for ABB’s Process Industries business unit, said: “Optimisation of mining and mineral processing operations in order to improve productivity, reduce downtime and protect workforce and the environment is essential and an important factor in being competitive in the market.

“The ABB Ability MineOptimize portfolio offers open, digitally connected mining applications for unmatched operation, maintenance, process and production performance. As digital transformation partner ABB Ability MineOptimize enables IT/OT integration for some of the world’s most cost effective mines.”

ABB will roll out new electrification solutions, digital applications and collaborative services in the MineOptimize portfolio throughout the year, it said, to:

  • Enable sustainable mining by powering the all-electric mine;
  • Re-invent mining automation with the next generation of ABB Ability™ System 800xA for Process and Power Control, and;
  • Improve availability through enhanced collaborative services with new predictive cloud based analytics for grinding, hoists and conveyors.

The new MineOptimize digital applications complement electrification and automation solutions and dedicated mining systems for hoists, gearless or ring geared mill drives and material handling which can be applied in the building or revamping of a mine, ABB said. They will also sit alongside collaborative remote assistance, availability, performance and quality services.

Pure Gold looks at mine electrification options for Madsen underground project

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In another sign that the underground mining space is increasingly going electric, Pure Gold Mining has said it intends to use a combination of diesel and battery-powered load and haul equipment at its Madsen underground gold project in Ontario, Canada.

The company said all ramp and level waste development would be performed by an owner-operated fleet of one- and two-boom electric hydraulic drill jumbos, 3 cu.m capacity LHDs, 20-t haul trucks, scissor lift/bolters and other rubber tyred support equipment.

Pure Gold said: “Mining will be facilitated by a combination of diesel and battery-powered equipment, with diesel equipment being utilised for upper levels of the mine prior to refurbishment of the existing shaft and installation of a new double-drum production hoist.”

Following the refurbishment, battery-powered equipment is likely to be used, with the company explaining that its use will “eliminate emissions associated with the movement of ore and waste and will result in materially reduced ventilation and heating requirements”.

This information came out in the company’s press release announcing a feasibility study on Madsen, a former operating gold mine in the renowned Red Lake district.

Based on a probable mineral reserve of 3.5 Mt at 9 g/t, containing 1 Moz of gold, the company outlined a 12-year operation at Madsen, producing an average of 80,000 oz/y at an all-in sustaining cost of $787/oz.

The initial capital requirement of C$95 million ($71 million) would be paid back with an after-tax net present value (5% discount) of C$247 million (using a gold price of $1,275/oz), the company said.

Darin Labrenz, President and CEO of Pure Gold, said: “The Madsen-Red Lake orebody is an exceptional foundation on which to build a gold mining company. With access to existing infrastructure, a high-grade reserve, and exceptional growth potential, Madsen is one of the outstanding gold deposits in Canada.”

He added: “The completed study outlines a long life high-margin mine, with low initial capital requirements and a fast timeline to production. In addition, specific exploration targets and satellite resources not considered in the feasibility study suggest an opportunity for near-term growth to potentially further enhance the economics of the project.”

The feasibility study supports a high-grade 800 t/d underground mining operation with designed stopes containing 1 Moz of probable reserves, the company said. Madsen benefits from significant mining, milling and tailings infrastructure already in place, resulting in one of the lowest capital intensity, undeveloped gold projects in the world, according to Pure Gold.

Mining will be conducted from new ramp development using a combination of cut and fill and longhole mining methods. A new hoist house and double drum production hoist will use the existing shaft infrastructure to hoist ore and waste from the mine, commencing in year four of operations.

The Madsen implementation schedule spans a period of 13 months, with underground mine development commencing approximately nine months before the first gold pour. The initial capital outlay of C$95 million (including contingency) supports the construction of an underground mine and associated infrastructure, including the expansion of existing milling capacity to 800 t/d of ore.

Assuming the project execution starts in April, the first gold production would be expected in May 2020.

JDS Energy and Mining led the feasibility study, which included contributions from consultants such as Knight Piésold, Nordmin Engineering, MineFill Services, Integrated Sustainability, Lorax Environmental Services, Ginto Consulting and Equity Exploration Consultants.

Dana Off-Highway expands electrification offering with launch of new drivetrains

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Dana has introduced two new electric drivetrain solutions for off-highway vehicles, including the Spicer® Electrified™ e-Axle and e-Gearbox.

These technologies enable electrified propulsion within established vehicle architectures by leveraging the company’s portfolio of motors, inverters, and controls, Dana said.

“Dana, through numerous organic and inorganic initiatives, has filled out its product portfolio to support the needs of its customers,” the company said. “The company will debut its electrified drivetrain solutions in April at Bauma alongside e-Propulsion technologies from the SME Group, which the company acquired earlier this month. These electrodynamic solutions support customers’ needs for efficiency, manoeuvrability, safety, and overall performance.”

Aziz Aghili, President of Dana Off-Highway Drive and Motion Technologies, said: “Vehicle manufacturers in mining, construction, and other off-highway markets are efficiently transitioning toward electrification, while retaining a large portion of their products in traditional technologies.

“Dana has positioned the company to be energy-source agnostic to support our customers across drivetrain configurations, including electrodynamic components that accelerate the adoption of electrification through the introduction of technologies specifically selected to meet the needs of current vehicle architectures.”

The Spicer Electrified e-Axle combines Dana’s heavy-axle design with a high-efficiency TM4 SUMO™ HP motor/generator and inverter combination for medium-sized mining trucks, medium-sized load haul dumpers, and large lift trucks.

Supplying 139 kW of continuous power and 193 kW at peak power, the TM4 motor/generator and inverter are joined at the centre housing of the axle to provide needed torque and efficiency within the space typically allotted for an internal-combustion engine and transmission.

The Spicer Electrified e-Gearbox features a compact design that manages high input speeds and accommodates the installation of an electric motor. “It offers a highly engineered interface for connecting cost-effective motors used in electrification with conventional Spicer hydrostatic transmissions,” Dana said.

Its plug-and-play design combines Dana-supplied TM4 and SME electric motors with Spicer hydrostatic transmissions for small- and medium-sized wheel loaders up to 10 ts and telehandlers with lift capacities up to 6.8 t.

The e-Gearbox will be available for customer testing in the second half of 2019.

Dana said: “The electrified propulsion technologies shown by Dana at Bauma (stand A3 325) will reflect the series of strategic moves made by the company to support electrification and hybridisation in the off-highway market over the past two years, including:

  • “The acquisition of the power-transmission and fluid power businesses of Brevini;
  • “The acquisition of a majority stake in TM4, a manufacturer of high-voltage electric motors, power inverters, and control systems;
  • “An agreement to purchase the Drive Systems segment of the Oerlikon Group, and;
  • “The acquisition of the SME Group, a designer and manufacturer of low-voltage motors and inverters.”

Combined with the company’s expertise in driveline technologies, sealing systems, and thermal management, these initiatives position Dana as the leading supplier of electrification solutions for the off-highway segment, the company said.

Pon brings 26 t battery-electric excavator to Norway construction site

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Pon Equipment, together with Caterpillar, has developed the world’s first battery-electric 26 t excavator, according to Norway-based construction company Veidekke.

After extensive testing with a prototype, eight machines are now in production, with the very first in use by Veidekke.

While not in the same class as mining excavators, this battery-electric machine is another example of OEMs manufacturing diesel alternatives with increasingly larger payloads and batteries.

Veidekke’s Knut Egge said in a press release (translated from Norwegian) that the company wanted to reduce its greenhouse gas emissions and, at the same time, increase its competitiveness, adding that the new excavator would save some 52 t/y of CO2 emissions compared with the diesel alternative.

The rechargeable battery-powered excavator is a remodeled Caterpillar 323F Z-line used for the loading of trucks, Veidekke said.

The excavator is enabled by Danfoss’ EDITRON drivetrain, according to Tomi Ristimäki, OEM Sales Director at Danfoss EDITRON.

The machine is able to operate for up to seven hours on a single battery charge under nominal load, according to Danfoss. “The electric excavator is zero emission, and significantly quieter than the former diesel machine, which makes it ideal for use in urban areas with noise restrictions,” the company added.

EDITRON powertrain systems are rugged and compact, with smart software controls suitable for hybrid and electric applications within the power range of 30-2,000 kW, according to Danfoss.

Pon Equipment CEO, Erik Sollerud, said the company’s mechanics have been rebuilding, adapting and testing the battery-electric machines for over a year together with specialists from Caterpillar. Among other things, the engine, diesel tank, and some equipment have been replaced with electric motors, motor controllers and heavy-duty lithium batteries, he added.

Construction machinery in Norway, according to Statistics Norway, accounts for a total of 650,000 t/y of CO2 emissions.