Rolls-Royce Power Systems is making progress in the development of hybrid propulsion systems for mining haul trucks with the aim of improving operational efficiency and reducing CO₂ emissions in open-pit operations.
The company confirmed it will begin field testing in the fall of 2026 with a pilot vehicle equipped with MTU hybrid technology at an as-yet-undisclosed mine. The system combines MTU 4000 Series engines with a high-performance electric powertrain designed to recover energy during descents and reuse it during the trucks’ ascents.
According to the company, this configuration can reduce fuel consumption and carbon emissions by up to 30% compared to conventional propulsion systems.
Energy recovery to optimize mining operations
The hybrid system developed by Rolls-Royce stores the energy generated during downhill braking in batteries. This energy then powers the electric motors in the wheels during periods of peak energy demand.
Thanks to this process, the diesel engine operates with lower workloads and improves vehicle efficiency on demanding journeys within open-pit mines.
Likewise, the design includes a modular and scalable architecture that allows the technology to be adapted to different truck models, topographic profiles, and operating conditions.
Mining seeks to reduce costs and emissions
The mining industry faces increasing pressure to reduce its carbon footprint as global demand rises for critical minerals used in electromobility, data centers and technologies associated with the energy transition.
Cobus van Schalkwyk, global vice president of Mining at Rolls-Royce Power Systems, explained that trucking represents one of the biggest sources of costs and emissions within mining operations.
Schalkwyk emphasized that transportation in open-pit mining represents a significant portion of production costs and CO₂ emissions. Hybrid systems offer an effective tool for reducing both factors.
The world’s leading mining companies maintain emissions reduction targets of between 30% and 40% by 2030 and climate neutrality goals by 2050.
Hybrid technology to modernize existing fleets
One of the main focuses of the project is to enable the modernization of already operational transport trucks through retrofit solutions, avoiding the total replacement of fleets.
This approach seeks to accelerate the adoption of decarbonization technologies without compromising the continuity of operations or making massive investments in new equipment.
For decades, MTU engines have been used in heavy mining equipment such as drills, excavators, loaders, and haul trucks. The 4000 Series has been designed for continuous, demanding operations, and several versions are currently certified to run on sustainable HVO (hydrogenated vegetable oil) fuel.
The company will officially present the hybrid concept during the Electric Mine Conference to be held on May 7, 2026 in Lisbon, Portugal.
Source: Rolls-royce
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