The mining industry is going through a major shift. Tightening environmental laws, higher fuel costs and world-wide efforts to reduce carbon emissions are driving the change. Mining companies, and the makers of heavy-duty equipment they use, are all talking about the new energy mining trucks. These are the big trucks that don’t have a traditional diesel engine. Instead, they’re powered by electric or hybrid-electric systems. These trucks promise better gas mileage, lower greenhouse gas emissions and big money saved over time. However, the switch to battery-powered mining vehicles has added a big problem to the engineer’s to-do list. You have to figure out how to keep the high-capacity battery packs at the right temperature.
This article will explain the unique liquid cooling needs of these new energy mining trucks. I’ll also address the hot topics in the minds of people in this industry about this issue.
Over the past ten years or so, the mining industry has gotten a lot of pressure to buy cleaner, more efficient equipment. The diesel trucks that have always been the heart of the mining business now have some problems. First, fuel costs are sky-high. Second, the maintenance you need to do on diesel trucks is taking more time and getting more expensive. Finally, everybody around the mine wants more sustainability by the mining companies. The trouble is, the mining companies can’t just stick a wind turbine or some solar panels up to cover the mine and all its equipment.
In response, many of the world’s largest mining companies along with several truck manufacturers are in the process of designing, building or even operating these battery electric or hybrid-electric mining trucks. The new energy mining trucks market is experiencing robust growth. Valued at USD 6.5 billion in 2022, it is projected to reach USD 12.4 billion by 2030, demonstrating the increasing adoption of these vehicles in mining operations. The overall mining truck market is also expanding, with expectations to grow from USD 27.45 billion in 2023 to USD 37.39 billion by 2028, at a compound annual growth rate (CAGR) of 6.4%.
They are doing this because these vehicles offer many possible good things. These could be things like: reduce the noise in the mine. Make the truck work way better. Cut down on the carbon footprint of the mine. These give mining ops some excellent benefits. For an underground mine, which is different from a surface mine, you can make the mine air a lot safer for the miners who are down in the hole. You have the chance to use a lot less diesel fuel at the mine. You could even get cheaper electricity at the mine if you could get your power from some renewable way to make electricity.
People want to go to the new green trucks. Lots of folks are driving the change. However, when you look at a big battery pack, that’s a lot of power, a lot of kilowatt hours, in one place. When you beef up that power to climb a big hill carrying a huge load, you are going to make some heat! This is where using liquid to move heat becomes super important. If you don’t move that heat out of there quick, you are going to kill something and maybe somebody. So, a simple liquid cooling system is the key to make the battery packs last, be safe, and make the truck go up the hill like it should all the time.
In the world of electric mining trucks, the battery system is both a critical and expensive component. Battery degradation is directly influenced by heat; excessive temperatures can accelerate chemical wear, shorten battery life, and compromise safety. In worst-case scenarios, overheating can lead to catastrophic battery failure or thermal runaway events, which no operator can afford to risk in a production-critical environment. Conversely, operating batteries in extremely cold conditions without sufficient temperature regulation can also degrade their performance, reducing energy output and increasing charge times.
A robust liquid cooling system mitigates these risks by managing temperature fluctuations more efficiently than passive or air-cooling methods. Liquid coolants, typically composed of water-glycol mixtures or specialized fluids with superior heat capacity, circulate through channels around the battery cells. By doing so, they transport heat away from the cells rapidly and dissipate it through heat exchangers or radiators, ensuring the battery remains within an optimal temperature range.
Mining environments present additional complexities. Trucks travel across rough terrain, work under punishing load cycles, and must remain operational in all weather conditions, from scorching deserts to frigid subarctic regions. The continuous stress and extreme conditions escalate the importance of a cooling system that is robust, durable, and easy to maintain. Effective cooling not only optimizes performance but also extends service intervals, reducing downtime costs—an essential consideration when each minute of truck inactivity in a mining setting translates to lost productivity.
Designing liquid cooling systems for these big batteries in these new energy mining trucks is different because:
1. High Thermal Load
New energy mining trucks carry significantly larger battery packs than passenger vehicles. The heat generated can be tremendous, particularly during intense operations such as hauling or climbing steep grades with full loads. A powerful pump and large-diameter coolant lines may be needed to ensure adequate coolant flow rates.
2. Harsh Operating Conditions
Ever been on a mine site? Dust and dirt are everywhere. Everything vibrates with the noise from the big rock trucks, dozers, and front-end loaders running around. Any cooling system must withstand these environmental stresses without leaking or clogging. The materials and seals used must be corrosion-resistant and designed to handle fluid chemistry variations.
3. Scalability and Modularity
Mining operations often expand or reconfigure their fleets, requiring batteries with varying capacity needs or performance profiles. A modular cooling system offers greater flexibility. If capacity demands change, cooling loops can be extended or reconfigured without redesigning the entire system.
4. Energy Efficiency
Cooling pumps and fans are parasitic loads—energy spent powering them is not used for vehicle propulsion. Minimizing this energy consumption is vital to preserving the battery’s range. Advanced sensor-driven control strategies help by activating cooling only when needed, ensuring the system is as energy-efficient as possible.
5. Maintenance and Reliability
Remote mining sites often have limited maintenance resources. Downtime is costly, and quick fixes must be practical. A robust design and readily available replacement parts are essential for ensuring uptime and avoiding supply chain disruptions.
Prospective customers in the new energy mining truck sector typically raise various concerns about liquid cooling systems. Here are some questions we get asked all the time:
We primarily employ aluminum for its desirable combination of lightweight properties, corrosion resistance, and thermal conductivity. In situations where clients demand heightened durability, we also use some copper alloys. The specific selection depends on factors such as required heat transfer performance, ambient environmental conditions, and customer preferences regarding weight constraints.
Absolutely. In our design process, we account for peak heat generation that occurs in heavy-duty operations. By optimizing fluid channel geometry and wall thickness, we ensure plates distribute coolant efficiently, preventing localized overheating. Tests simulating multi-hour operations at full load have shown that our plates keep battery temperatures within safety margins, prolonging cell longevity.
Yes, we have a dedicated engineering team that collaborates closely with clients to tailor plate dimensions, channel layouts, inlet/outlet configurations, and mounting points. In addition, our flexible tooling processes enable us to adapt quickly to non-standard form factors. This customization ensures the thermal solution aligns perfectly with each battery pack’s architectural nuances.
Our modern manufacturing facilities can deliver thousands of plates per month, supported by automated processes like CNC machining, brazing, and robotic assembly. Should mining fleets grow, we can escalate output by adding production shifts or expanding facilities. Thanks to our global supply chain, we maintain steady material availability that aligns with market needs.
We have successfully fabricated plates ranging up to 1.5 meters in length, and we can produce even larger units if the project demands it. For those unique configurations, we conduct thorough structural and thermal modeling to confirm the plate’s integrity and cooling capabilities remain uncompromised.
Mining environments often oscillate from bitterly cold mornings to punishing midday heat, prompting the need for a wide operational temperature range. Our plates are tested to function reliably from -40°C (-40°F) to over 80°C (176°F). We use specialized gaskets and seals that resist hardening in cold weather and maintain their elasticity under high temperatures, ensuring secure fluid containment.
Yes, in-house testing is a core component of our R&D cycle. We use environmental chambers to simulate temperature swings, and we employ flow visualization techniques to ensure uniform distribution of coolant. We also replicate real-world driving patterns with high-current discharge cycles, confirming that our plates mitigate damaging temperature spikes.
Our manufacturing processes conform to ISO 9001 quality standards. Depending on the target market, we offer plates that comply with additional regulations, such as CE marking for European applications. If customers require further region-specific certifications, our engineering and regulatory teams can assist in achieving those standards.
We have over a decade of experience designing cooling solutions for electric buses, construction machinery, and mining trucks. This background equips our staff with the practical knowledge required to handle high-current scenarios, rugged terrain vibrations, and extended duty cycles typical of such platforms.
Yes. Our plates are often part of a broader thermal loop that might include cooling tubes, radiators, and active heating elements.
With proper coolant maintenance, our cold plates typically last 8 to 10 years or more, matching or exceeding the operational life of many battery systems used in mining trucks. We select alloys, coatings, and bonding processes that withstand extended exposure to vibration, pressure fluctuations, and thermal cycling.
We design our plates to accommodate a range of coolants, including water-glycol mixtures, dielectrics, and specialized fluids with corrosion inhibitors. Our technical team collaborates with clients to confirm the fluid’s compatibility with the chosen alloy, thereby optimizing performance and extending product life.
Certainly. We have supplied liquid cooling assemblies for large mining trucks in South America, high-load construction machinery in Asia, and electric buses in North America. In each project, we utilized a combination of cold plates, tubes, and manifolds to deliver robust thermal management. These real-world implementations speak to our ability to handle complex, large-scale requirements.
We leverage computational fluid dynamics (CFD) to optimize channel geometry and eliminate hot spots. By balancing inlet and outlet flow, we achieve even heat removal across the entire plate. Our specialized flow balancing valves also allow fine adjustments in real-time, enabling consistent temperatures during high-load scenarios.
Yes, complex geometries are one of our specialties. We have the expertise and equipment to fabricate curved, angled, or multi-level plates that conform to unconventional module layouts. This is crucial for OEMs looking to maximize energy density while maintaining effective heat dissipation.
During scaled-up manufacturing, we adhere to strict process controls:
We maintain statistical process control (SPC) data, giving us real-time visibility into production quality.
Robust cooling systems are instrumental for heavy electric trucks, facing intense loads and environmental extremes. By preventing leaks, blocking corrosion, and preserving thermal balance, mine operators realize longer battery lifespan and safer processes. Strategically chosen materials, expertly calibrated flow dynamics, and rapid fault detection unify into a secure, high-performing solution. With its engineering expertise, XD THERMAL offers proven, end-to-end thermal management services, fueling progress in the demanding realm of new energy mining trucks while respecting cost efficiency, durability, and environmental standards.
EN 
DE 
ES 
KO 