BHP and Rio Tinto have begun on-site trials of Caterpillar’s battery-electric haul trucks in Western Australia’s Pilbara region, marking a key step in efforts to reduce emissions from large-scale iron ore operations.
Australia’s first Cat 793 XE “Early Learner” battery-electric haul trucks have arrived at BHP’s Jimblebar mine and are now undergoing commissioning ahead of operational testing. The joint initiative brings together BHP, Rio Tinto and Caterpillar to assess the performance, infrastructure requirements and operational impact of zero-exhaust emission heavy haulage technology.
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The mining companies said the trials will focus on whether battery-electric trucks can eventually replace diesel-powered fleets without compromising productivity. Key areas under review include battery performance, charging systems, power management and the broader supply chain needed to support electrified operations.
“Replacing diesel haulage is not just about swapping out one machine for another,” said Tim Day, President of BHP Western Australia Iron Ore. “It requires rethinking the entire system, including how we generate, store and manage power, as well as how those components work together in a live mining environment.”
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Support for the project is being provided by Caterpillar dealer WesTrac, which is assisting with technical development and trial operations as the companies explore how fleets could transition once commercial deployment becomes feasible.
Rio Tinto’s managing director of Iron Ore Pilbara Mines, Andrew Wilson, said the scale of the challenge requires extensive collaboration across the industry. “Decarbonising our haul truck fleet across 18 Pilbara mines is a massive undertaking, and no single company can achieve zero-emissions haulage alone,” Wilson said. “Working with BHP and Caterpillar allows us to share learnings and develop solutions that align with our net-zero ambitions.”
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Caterpillar said the Pilbara trials would provide real-world operational data critical to future product development. “The arrival of these Early Learner trucks is a significant milestone,” said Marc Cameron, Caterpillar’s Senior Vice President. “Working directly with customers in active operations allows us to solve challenges in real time and accelerate innovation.”
Following the initial joint testing phase, BHP and Rio Tinto will independently assess the results to determine the timing and scale of further deployment within their respective operations. Data collected during the trials is expected to guide future investment decisions related to power infrastructure, charging networks and fleet integration.
