World’s Largest BEV Truck Unveiled by Liebherr and Fortescue at MINExpo in Las Vegas

In 2022, Fortescue and Liebherr first announced a partnership to develop and supply 120 green mining haul trucks. At MINExpo 2024 recently in Las Vegas, Nevada, the two companies revealed that the deal had expanded threefold to a total of 360 mining trucks. These trucks will not only be battery-electric but also autonomous, featuring Liebherr’s T 264 model. This landmark agreement between Liebherr and Fortescue marks a significant step toward zero-emission mining and supports the decarbonization goals of both companies.

All trucks in this fleet will eventually be equipped with a zero-emission battery power system developed by Fortescue Zero, along with a jointly developed Autonomous Haulage Solution (AHS). Both systems are designed to be scalable, allowing them to be retrofitted onto existing Liebherr haul trucks. Currently, four of these autonomous trucks are undergoing validation at Fortescue’s testing site in Australia, with full validation of the autonomous battery-electric solution expected by early 2026.

The Liebherr-Fortescue deal encompasses a total of 475 electric mining machines, including 360 autonomous, battery-powered T 264 trucks. This fleet represents a significant shift towards sustainable mining operations.

The first of these trucks began arriving at Fortescue’s operations in Western Australia in October, starting with diesel-powered models that are being converted to electric. However, the majority of the fleet will eventually be delivered as fully battery-electric units.

Currently, Fortescue is testing four autonomous Liebherr T 264 trucks, with plans for fully operational autonomous models to be in place by the first quarter of 2025. Testing of the entire fleet, including the battery-electric and autonomous systems, is expected to conclude in early 2026.

The mining trucks in the Fortescue and Liebherr partnership are powered by a 3.2-megawatt-hour battery developed by Fortescue Zero, the technology arm of Fortescue, an iron-ore mining company. To support the efficient operation of these massive battery-electric haulers, the companies have also developed a static charging solution capable of quickly recharging the batteries in just 12 to 58 minutes.

In addition to the powerful battery system, the trucks are equipped with an Autonomous Haulage Solution (AHS) designed to streamline the recharging process at mine sites. This system helps prevent delays by coordinating truck recharges, ensuring that vehicles do not line up and wait for charging, thereby optimizing fleet efficiency and minimizing downtime during operations.

The Liebherr T 264 mining truck is part of Liebherr’s 240-ton size class, matching its ultra-class hydraulic excavators, as well as electric shovels and wheel loaders. The massive truck’s unique hybrid combination of a 2,700 hp Cummins QSK 60 engine features Particulate Matter (PM) emission reductions up to 63%, an efficient Litronic Plus AC drive system and powerful electric wheel motors (4,425 hp) allow for faster cycle times, making the T 264 an exceptionally productive and cost-efficient truck. Its gross vehicle weight (GVW) is 416.00 t, with an impressive gross power of 2,013 kW.

Liebherr PR 776 Mining Dozers and R 9400 E Electric Excavators

In addition to the haul trucks, the expanded contract includes 60 electric Liebherr PR 776 mining dozers, also equipped with Fortescue Zero’s battery power system. The deal further includes 55 R 9400 E electric excavators, three of which are already operational across Fortescue’s mining sites. This comprehensive partnership showcases a major push toward sustainable mining operations and the adoption of innovative, emissions-free technologies.

A Large Scale Zero Emission Mining Ecosystem

Together, Fortescue and Liebherr are set to develop and validate a comprehensive range of zero-emission mining solutions, aiming to establish a fully operational zero-emission mining ecosystem by 2030. This partnership is expected to result in one of the world’s largest zero-emission mining fleets, marking a groundbreaking shift in the mining industry’s move away from fossil fuel dependence.

The pioneering technologies developed through this collaboration, including battery-electric and autonomous systems, will be made available to mining companies worldwide once they enter series production. This global availability promises to accelerate the transition to sustainable mining practices across the industry.

This deal, encompassing all the equipment and technological advancements, is the largest in the 75-year history of the Liebherr Group. Beyond its immediate impact, it will generate significant long-term benefits, especially for Liebherr-Australia. The company is preparing its branches and remanufacturing facilities to safely and efficiently maintain this new fleet, presenting a unique growth opportunity and ensuring continued positive outcomes well beyond 2030.

Liebherr, a German-Swiss multinational equipment manufacturer, is headquartered in Bulle, Switzerland, with its main production facilities rooted in Germany. The company is structured into 11 divisions, which span a wide range of industries including earthmoving, mining, mobile cranes, tower cranes, concrete technology, maritime cranes, aerospace and transportation systems, machine tools and automation systems, domestic appliances, and components.

Liebherr operates globally with over 130 companies and a workforce of more than 53,000 employees. In 2023, the company generated revenue of over 14 billion euros. By 2007, Liebherr had become the largest crane manufacturer in the world, solidifying its position as a major player in industrial equipment and heavy machinery. The company continues to innovate across multiple sectors, including its recent focus on zero-emission mining technologies through partnerships like the one with Fortescue.

Fortescue, a global metal mining company headquartered in Australia, was primarily focused on iron ore mining under the name Fortescue Metals Group (FMG) until July 2023. As of 2017, Fortescue ranked as the fourth-largest iron ore producer in the world. The company has extensive mining holdings, covering more than 87,000 square kilometers in the Pilbara region of Western Australia, making it the largest tenement holder in the state—surpassing even major mining giants like BHP and Rio Tinto.

Fortescue has played a pivotal role in the global iron ore market and continues to expand its influence with new ventures, such as its recent transition into clean energy technologies, including battery-electric mining equipment and zero-emission initiatives. This shift underscores the company’s evolving strategy toward sustainability and decarbonization.