Vale announced that its partner Cummins Inc. has started the successful commissioning of a new ethanol fuel test cell, marking a significant milestone in both companies’ joint project with Komatsu to develop an ethanol/diesel-powered surface mining haul truck aimed at reducing greenhouse gas emissions. This achievement underscores the three companies’ shared commitment to decarbonising the mining sector and advancing sustainable energy solutions.
Announced in July 2024, the dual fuel programme aims to retrofit existing diesel engines in Komatsu haul trucks to operate on both ethanol and diesel, significantly enhancing sustainability. These modified 230–290-ton haul trucks – the first vehicles of this size to run on ethanol in the tank – will be able to use up to 70% ethanol, potentially lowering CO2 emissions footprint by up to 70%. QSK60 Engine testing is expected to run until 2026 before field tests begin at Komatsu’s facilities.
“We continue to make progress on our decarbonization projects, reinforcing Vale’s commitment to this issue,” Carlos Medeiros, Vale’s Executive Vice President of Operations, stated. “Ethanol is a priority input to achieve our goal of reducing the use of diesel in our operations while keeping reliability and operational excellence.”
Vale has set a target of reducing its scope 1 and 2 greenhouse gas emissions by 33% by 2030. Among mine equipment, the haul truck is one of the biggest consumers of diesel and therefore a major emitter of greenhouse gases. The election of ethanol as an alternative to diesel is justified because it is already a widely adopted fuel in Brazil, with an established supply network.
“Ethanol/methanol diesel dual fuel systems offer significant benefits to the mining industry, including the realisation of up to ~70% decarbonization – lowering harmful emissions such as carbon dioxide, nitrogen oxides, and particulate matter – while continuing to meet comparable productivity and performance requirements,” said Luke Mosier, Cummins Innovation Program Leader. “More than that, miners who utilize alternative fuels can utilize their existing infrastructure and leverage their current fleet, facilities and personnel.”
“Our ongoing dual fuel project, developed in close collaboration with Cummins and utilizing a blend of ethanol and diesel, is an important bridge technology aimed at supporting Vale’s near-term decarbonization goals,” said Dan Funcannon, Senior Vice President, Surface Haulage, Komatsu. “This initiative reflects our shared commitment to practical, scalable solutions that advance sustainable mining. The launch of the dedicated test cell is an exciting milestone as we continue to develop and deploy low-carbon technologies for the future of haulage.”
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