BHP, Rio Tinto and Cat trial battery-electric haul trucks in the Pilbara

BHP, Rio Tinto and Caterpillar have launched an industry-first trial of two Cat 793 XE Early Learner battery-electric haul trucks at BHP's Jimblebar iron ore mine in Western Australia's Pilbara region, marking a significant step in the effort to reduce greenhouse gas emissions from large-scale mining operations.

The trucks completed extensive safety validation and controlled testing at Caterpillar's Tucson Proving Ground in the United States before arriving at Jimblebar late last year.

After three months of on-site testing, the trial has now logged more than 100 hours of operation and over 200 test laps, generating data on safety, technology performance and maintenance requirements.

Jimblebar is home to two of seven Caterpillar Early Learner battery-electric haul trucks currently being tested globally. The Pilbara's scale and operational intensity were key factors in selecting the site, with the trial assessing technical readiness, infrastructure needs and commercial feasibility — including both static and dynamic high-powered charging solutions.

Western Australia Premier, Roger Cook, and Mines and Petroleum Minister, David Michael, joined representatives from BHP, Rio Tinto, Caterpillar and WesTrac to observe the trucks in operation.

BHP President of Australia, Geraldine Slattery, said the trial was central to the company's decarbonisation strategy.

"Investing in battery-electric haul truck fleet technology and operations in the Pilbara is key to our decarbonisation," she said, adding that BHP remains on track to achieve at least a 30 per cent reduction in operational greenhouse gas emissions by FY2030 from FY2020 levels.

Rio Tinto Iron Ore Chief Executive, Matthew Holcz, said the trial would provide real-world data under some of the most demanding operating conditions on earth, and that the Pilbara's unique scale made it the right environment to understand what broader deployment would require.

Caterpillar Resource Industries Vice President of Product Management, Thad Litkenhus, said the collaboration was helping validate battery-electric trucks and charging infrastructure in the exact conditions customers face.

"What matters is how we translate what we're learning into better outcomes, from improved energy efficiency to supporting lower emissions and more reliable performance at site," he said.

“The progress we’re seeing is helping accelerate the development of solutions that our customers can implement with confidence.”

The next phase of the trial will evaluate dynamic charging via an energy transfer system capable of charging the trucks while in motion, which the companies saidcould be critical to operational efficiency at scale.