Electrification, combined with digital-isation, automation and higher-efficiency equipment, could help mines reduce energy consumption, improve reliability and lower operating costs, technology and electrification company ABB Southern Africa executives said during a panel discussion at Electra Mining Africa 2026 last month.

Although electrification is becoming the foundation of the modern mine, it should not be viewed simply as replacing diesel equipment with electrically powered alternatives, said ABB Southern Africa local business mine manager for automation process industries Charl Marais.

ABB’s eMine portfolio aims to electrify mining assets from pit to port, including haulage trucks, mills, ventilation systems and charging infrastructure.

“The ABB eMine trolley system can reduce diesel consumption by up to 90% while trucks operate on the trolley system, [and] ABB’s eMine FastCharge solution provides automated charging at up to 600 kW.”

The value of electrification can be increased when combined with automation and digitalisation, Marais added.

Many mining operations still have separate automation systems for individual processes, with power systems, process control, equipment monitoring and operational data managed independently. ABB’s approach is to connect these systems so that mines can coordinate energy use, process control, asset performance and operational decision-making through an integrated platform.

ABB Southern Africa electrification commercial leader and electrification distribution solutions division manager Egon Worthmann said mines should consider digital capability, efficiency and reliability when investing in electrical equipment.

“The most immediate opportunity arises while you’re electrifying; [by] really invest[ing] in equipment that is digitally enabled, [you] can digitally connect to the systems that can use data to establish where [and] how energy is generated, distributed [and] consumed within mining operations,” he elaborated.

Digitally connected equipment enables mines to identify where efficiency improvements and investment are most needed. Condition monitoring also supports maintenance based on equipment condition, rather than fixed schedules, consequently improving reliability.

Worthmann cited medium-voltage switchgear equipped with sensor technology as an example, as the technology can monitor current and voltage without relying on traditional current and voltage transformers, with the switchgear having a lower energy footprint.

He cited reliability, efficiency of equipment, and having that knowledge to go forward as important elements when building the business case for electrification.

Significant energy savings can also be achieved by improving motor efficiency and controlling motors operation, said ABB motion senior VP Graham Abrahams.

About 80% of motors installed in the mining industry in Southern Africa are at IE1 or IE2 efficiency levels, according to ABB’s assessment.

“Applying a variable-speed drive (VSD) to suitable applications could reduce energy consumption by about 25%, while combining higher-efficiency motors with [VSDs] could increase the potential saving,” he added.

ABB’s IE5 synchronous reluctance motors are designed to reduce energy losses by up to 40%, compared with IE3 motors.

VSDs are particularly useful for applications such as pumps and fans, where equipment does not always need to operate at full load. The drive can adjust motor speed in line with demand, thereby reducing energy consumption.

Marais said automation can deliver further savings at system level, citing ABB’s ventilation optimisation technology that uses the location of people and vehicles to control where ventilation is required.

The technology can reduce the amount of air supplied to unoccupied areas while maintaining adequate ventilation where personnel and equipment are operating, potentially reducing ventilation energy consumption by about 60% to 70%.

The executives also highlighted the importance of operational data as mines integrate renewable energy, battery storage and electrified equipment.

Worthmann said mines are increasingly incorporating renewable generation and battery storage, while the electrification of mining fleets is increasing demand for electrical energy.

“It’s not just data, you know, and collecting the data . . . But [with] the products that you actually invest in now, you need to consider even how those products are produced.”

Abrahams said connecting motors and drives to an automation system could provide a broader view of plant performance.

For example, if one conveyor motor is drawing more power or producing more torque than comparable motors, the system can flag the difference and potentially identify an emerging mechanical problem.

“This scenario allows you to make more intelligent decisions, and allows you to maintain the uptime,” he added.

The panellists said mines did not necessarily have to complete the transformation all at once.

Abrahams recommended that mines with limited capital expenditure consider upgrading large, older motors first and installing VSDs where applications allow.

Worthmann said mines should build digital connectivity into their electrification programmes to provide the data needed to facilitate energy efficiency and predictive maintenance.

Marais added that mining companies should first establish a technology roadmap showing how they intend to move from their current operating environment towards their desired future state.

“Understand how integration fits into that, and work with an [original-equipment manufacturer] or supplier that [can] provide all . . . these technologies in an integrated way so that you maximise the value you get out of it,” he concluded.