Proving Autonomy and Electrification at Scale

Mining companies worldwide face pressure to meet production targets while reducing their carbon footprint. EACON is proving that large scale deployment of autonomous battery-electric haul trucks or (BEV) can deliver both. EACON operates more than 450 pure battery-electric mining haul trucks, accounting for 60% of China’s total battery-electric mining haulage fleet, with over 5 million kilometres of proven, reliable performance across demanding mine conditions. At flagship sites, fleets of up to 120 battery-electric haul trucks operate as some of the largest autonomous electric mining fleets in the world. The EACON’s ORCASTRA® platform integrates autonomy with intelligent fleet and energy management. This solution is built on a data-driven model that predicts power usage for mining trucks, alongside a model for charging units. This eliminates downtime, cutting peak-hour electrical use by 13%, save more than 60% of energy costs compared to our hybrid electric models and up to 70% compared to diesel models and reduces on-site manpower for charging activities by 30%. By combining autonomy and electrification, EACON is building a blueprint for zero carbon mining that can be replicated globally.Compared with traditional diesel models, our hybrid-electric EL100 driverless mining trucks can improve fuel efficiency by 25 to 30%, while pure electric models can further save more than 60% of energy costs compared with our hybrid-electric driverless mining trucks. In addition, each vehicle can achieve an annual carbon dioxide emission reduction of 3,978.5 kilograms.

Setting the Stage

• Sites: Large-scale open-pit coal, metals, and quarry operations

• Commodities: Coal, limestone, copper-gold, iron ore

• Operating Environment: Harsh climates, 24/7 production

• Fleet Before Project: Conventional diesel trucks

• Scale: 450+ BEVs deployed, 5 million+ km of cumulative operation, 60% of China's BEVs

The Decarbonisation Imperative

With net zero deadlines fast approaching, the mining sector is under mounting pressure to decarbonise without compromising output. Conventional diesel fleets can contribute to high carbon intensity, rising fuel costs, and safety risks. Transitioning to BEVs at scale is seen as a pathway to zero carbon operations, but challenges remain, including charging bottlenecks, infrastructure demands, and ensuring reliable 24/7 operations. Mine operators need a partner capable of integrating autonomy with electrification while preserving production efficiency. Stakeholders also seek tangible cost savings and solutions that can be scaled across different mine types. The challenge is not just replacing diesel, but proving that carbon zero haulage can deliver equal or greater reliability, safety, and efficiency in demanding mining environments.

Autonomous Electrification, Optimised at Scale

EACON has executed a fully electric autonomous haulage strategy, deploying in excess of 450 autonomous battery electric haul trucks across multiple mine sites. At key sites, fleets of 50 to 120 trucks run parallel to existing diesel and hybrid units, achieving annual production targets of 20 to 40 mega tonnes while demonstrating industrial-grade reliability. The entire operation is coordinated through the ORCASTRA® platform, which handles dispatching, real-time vehicle communication and full autonomy oversight, ensuring operational safety and efficiency in complex mining environments.Built in collaboration with OEMs including Yutong and Tonly, the trucks are equipped with drive-by-wire steering, regenerative braking and tight integration with EACON’s autonomous haulage systems (AHS) to maximise performance and cut emissions. To overcome charging challenges, EACON introduced an intelligent charging scheduling system. By forecasting energy demands, allocating charging stations dynamically and sequencing charge times, this system prevents low-power idle time, cuts peak electricity demand by 13% reduction in peak-hour electricity use and reduces labour demands for charging by 30 per cent.These autonomous battery electric haul trucks are designed to operate safely in mixed traffic, adjusting speed and steering in response to obstacles or changing road conditions. The OEM-agnostic architecture allows compatibility across different truck models. By fusing electrification, autonomy and advanced energy management, EACON provides a repeatable blueprint for zero carbon mining that enhances safety, increases efficiency and sustains high throughput without sacrificing reliability.

Performance Outcomes

• 450+ BEVs deployed, 60% of China’s total BEVs

• Over 5 million km cumulative operation

• Zero stalling incidents from battery depletion

• 60% lower energy costs compared to hybrid electric trucks

• 70% lower energy costs compared to diesel trucks

• 13% reduction in peak-hour electricity use

• 30% reduction in on-site manpower for charging activities

• Continuous, reliable 24/7 operations

• Significant emission reductions

• One of the world’s largest autonomous battery electrfleets

“The application of battery-electric autonomous mining trucks has achieved zero-carbon intelligence in haulage links. This not only fundamentally reduces the safety risks of traditional mine haulage, but also significantly improves efficiency,” said Bai Shenghua, Chief Engineer of the Hongshaquan 2 Open-Pit Coal Mine.

Key Takeaways

Scaling BEVs in mining requires a holistic approach that combines vehicle autonomy, energy optimisation, and strong integration with site operations. Traditional charging was the main bottleneck, and EACON’s automated scheduling solution proved decisive in unlocking efficiency. Equally important was operator engagement and training, which ensured rapid adoption. Phased fleet rollouts allowed sites to build confidence while maintaining production. Infrastructure investments in communications and charging hubs underpinned reliability. Key practices included predictive energy management, early planning for energy strategy, and close collaboration among OEMs, technology providers, and mine operators. These lessons form a practical framework for replicating zero-emission, autonomous mining operations globally, reducing carbon emissions while maintaining safety, production efficiency, and operational resilience.

Unlocking the Future of Autonomous Zero-Emission Haulage

EACON plans to further expand BEV deployments and introduce next generation energy technologies, including fast charging and battery swapping. Global opportunities are emerging to replicate this model across multiple commodities and geographies. By combining autonomy with electrification, EACON is setting a clear pathway for the mining sector to achieve carbon neutrality, while strengthening productivity and safety worldwide.