BHP and Rio Tinto Begin Testing Australia’s First Caterpillar Battery-Electric Haul Trucks in the Pilbara
Australia has reached a major milestone in its transition toward cleaner, more sustainable mining technologies with the arrival of the country’s first Cat® 793 XE Early Learner battery-electric haul trucks at BHP’s Jimblebar iron ore mine in the Pilbara. The deployment officially launches a groundbreaking on-site trial—developed in collaboration with Rio Tinto and Caterpillar—to evaluate how battery-electric heavy haulage can support large-scale mining operations in one of the world’s most important iron ore regions.
The Pilbara—long recognized as a powerhouse of Australia’s economy—has traditionally relied on diesel-powered fleets to move hundreds of millions of tonnes of iron ore each year. As global industries push to decarbonize supply chains, the arrival of these trucks signals a shift toward cleaner technologies that aim to deliver the same productivity while eliminating exhaust emissions.
A Landmark Collaboration for Next-Generation Haulage
The two Early Learner trucks were delivered through an industry-first collaboration involving BHP, Rio Tinto, and Caterpillar, marking one of the most significant joint initiatives yet undertaken to accelerate decarbonization in mining. These trucks represent the first step in a long-term plan to replace diesel haulage with zero-emissions alternatives without disrupting production.
Once the units are fully commissioned and all safety verifications are complete, they will enter active testing phases at Jimblebar. These trials will provide critical insights into the viability of battery-electric technology for large, continuous, and high-load operations, such as those found in the Pilbara’s world-class iron ore mines.
The testing program is designed to analyze multiple variables: battery performance under Pilbara heat, charging infrastructure compatibility, haul cycle efficiency, energy management systems, and integration with existing mine operations. Together, these learnings will help shape not only the next generation of haul trucks but also the operational models, workforce skills, and energy systems required to support a fully electrified mining future.
Supporting Industry-Wide Decarbonization Goals
Achieving large-scale decarbonization in the Pilbara will require advancements far beyond the haul trucks themselves. Both BHP and Rio Tinto have acknowledged that technologies such as battery storage, fast charging, renewable power generation, and energy distribution networks must evolve in tandem.
Working closely with Caterpillar—and with support from WesTrac—BHP and Rio Tinto intend to accelerate the maturity of these technologies to align with their greenhouse-gas reduction goals. Both companies are targeting net-zero operational emissions by 2050, making progress in heavy-equipment electrification a strategic priority.
After the joint testing phase concludes, BHP and Rio Tinto will independently evaluate the results to determine whether and when they will progress to large-scale deployments within their respective operations. Scaled trials could see dozens of battery-electric trucks introduced into everyday mine fleets, supported by new charging stations, energy storage systems, and onsite renewable generation.
Executives Highlight the Importance of Industry Collaboration
BHP Western Australia Iron Ore Asset President Tim Day emphasized that powering up the first battery-electric trucks in the Pilbara is far more than a technology upgrade—it represents a transformation of mining systems from the ground up.
“Replacing diesel isn’t just about switching energy sources,” Day said. “It’s about reimagining how we operate and building the technologies, infrastructure, and supply chains needed to support a fully electrified mining future. These trials are essential to understanding how battery technologies, charging infrastructure, power management systems, and logistics all come together on a working mine site.”
Day added that achieving meaningful progress requires patience, deep industry collaboration, and a long-term commitment to innovation. “This transition will take time to get right, which is why projects like these—where we learn alongside Rio Tinto and Caterpillar—are so critical,” he said. “We’re excited to see what these trials reveal about the breakthroughs necessary to accelerate this shift.”
Rio Tinto Iron Ore Pilbara Mines Managing Director Andrew Wilson echoed these sentiments, highlighting that decarbonizing heavy haulage across 18 Pilbara mines represents a formidable challenge.
“No single company can achieve zero-emissions haulage on its own,” Wilson said. “It takes an entire industry working together to develop solutions that meaningfully reduce emissions. That’s why this collaboration with BHP and Caterpillar is so important. By testing these trucks in real Pilbara conditions, we’re taking a crucial step toward transitioning away from diesel and achieving our long-term net-zero commitments.”
Caterpillar Inc. Senior Vice President for Resource Industries Sales Services and Technology Marc Cameron emphasized that the Early Learner trucks mark a significant turning point.
“The arrival of these trucks in the Pilbara is a major milestone on the path to a more sustainable future,” Cameron said. “Working closely with customers like BHP and Rio Tinto allows us to solve challenges together and accelerate the innovation needed for next-generation mining equipment.”
A Pathway to Full Fleet Electrification
Throughout the trial, engineers, operators, and technicians from all three organizations will gather data and monitor how the trucks perform across varying load cycles, terrains, temperatures, and operational demands. The findings will guide future truck designs, battery performance improvements, and charging infrastructure upgrades.
Successful test results could pave the way for:
- Expanded pilot fleets of battery-electric haul trucks
- Integration with renewable power, including solar and wind
- Implementation of ultra-fast charging systems to reduce downtime
- New workforce training programs to support electrified operations
- Long-term planning for fully electric mine sites
The broader ambition is to transition from diesel-powered fleets—currently one of the largest contributors to mining emissions—to cleaner and more energy-efficient systems that maintain productivity and enhance sustainability.
A Unified Commitment to a Low-Carbon Future
The collaboration between BHP, Rio Tinto, and Caterpillar underscores a shared vision: accelerating the development of practical, commercially viable, and operationally reliable zero-emissions solutions for mining. By testing these trucks under real-world Pilbara conditions, the partners are taking a definitive step toward reshaping the future of iron ore mining and reducing the carbon footprint of one of Australia’s most vital industries.
As the trials progress, the findings will inform how quickly battery-electric haul trucks can be deployed at scale—and how soon the Pilbara can transition toward the next generation of sustainable mining operations.
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