First Mode offers three mining truck retrofit solutions for Path to Zero™

Today, First Mode announced an expanded product mix, helping its partners begin and progress on their Path to Zero. Julian Soles, CEO: “The journey begins with our Hybrid Electric solutions, which are feedforward retrofits for converting diesel fleets today while enabling future conversions to full zero emission battery or fuel cell options at anytime.”

Before retrofit, an ultra-class haul truck in typical use will burn about one million litres of diesel fuel per year, producing around 2,700 metric tons of carbon dioxide. Globally, there are about 10,000 ultra-class haul trucks in operation. That’s 27 million metric tons of CO2 each year.

The first solution is a Hybrid Electric Vehicle (HEV) with regenerative battery pack. When the truck is descending a hill, it uses its wheel motors as brakes. The energy generated is captured by the batteries and later used to help power the truck. This regenerative braking and power reuse cuts down on fuel usage and carbon dioxide emissions by up to 30%, depending on conditions.

The HEV diesel engine, radiator, and fuel tank are untouched by the HEV retrofit. No new support infrastructure is needed, so the HEV is aimed at being a first step in the miners’ decarbonisation journey.

Then there is the solution First Mode is already known for – Fuel Cell Electric Vehicle or FCEV. “A large liquid hydrogen tank is the most energy-dense and cost-effective way to store energy on a zero-emissions vehicle. The radiator mounted in front of the tank is used to cool the fuel cells that power the truck.”

The fuel cells on both sides of the truck combine hydrogen from the tank with oxygen from the air to produce electricity to power the truck. The only byproduct of the fuel cells is water. Again there’s regen batteries but they have the same configuration as the HEV battery pack, so HEV owners have the option of proceeding to an FCEV retrofit without discarding retrofit work already accomplished.

Last but not least the Battery Electric Vehicle or BEV. The BEV main batteries are charged through regenerative braking and through a static multi-megawatt fast charging system. The radiator is used to maintain acceptable operating temperatures for the batteries and their associated power electronics.

Again these batteries have the same configuration as the HEV battery pack, so HEV owners could proceeding to an all-battery retrofit without losing the retrofit work already accomplished.

Path to Zero solutions will be widely available beginning in 2025. To ensure smooth integration with existing fleet management systems, First Mode will provide staff training and education, fuel sourcing and fuel security support, regular maintenance, and access to spare parts.

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