The role of lithium-ion batteries in the evolution of the mining industry

In recent years, three primary types of batteries have been the most widely used in industrial applications such as mining: lead-acid batteries, nickel-iron (Ni-Fe) batteries and lithium-ion (Li-ion) batteries. The latter, Li-ion batteries, are recognized for their versatility and high efficiency, making them suitable for a diverse range of applications due to their high energy density, relatively low self-discharge rate and lack of memory effect.

One of the most notable advantages of lithium-ion batteries is their ability to withstand numerous charge and discharge cycles without significant degradation in capacity. Unlike other battery technologies, which can experience a rapid decline in performance after a limited number of cycles, lithium-ion batteries can withstand hundreds of cycles while maintaining optimum performance. This endurance not only extends the battery life cycle but also translates into a more profitable long-term investment.

The memory effect, which used to be a common problem with traditional batteries, is not a concern with lithium-ion batteries. Unlike older batteries that require complete charge and discharge cycles to maintain their full capacity, lithium-ion batteries do not suffer from this phenomenon. The convenience of being able to charge at any load level adds significant value to the operation and prolongs battery life.

In the realm of cutting-edge, efficient solutions for mining applications, lithium-ion battery-based solutions herald a new era in more sustainable practices. In that context, Atlas Copco has positioned itself as one of the most advanced and reliable players in the last few years, providing solutions that seamlessly integrate cutting-edge technology to power mining operations efficiently and responsibly. This advanced approach not only addresses the immediate energy demands of mining applications but also underscores the commitment to reducing environmental impact while fostering a more sustainable future for the mining industry. Atlas Copco's Li-ion battery-powered solutions for power, light and compressed air offer improved productivity to the end customer, and safer, healthier working conditions. These solutions represent a strategic leap towards more energy-efficient mining practices, pushing the industry forward.

The recent launch of Atlas Copco’s B-Air, the world's first battery-powered portable screw compressor, marks a turning point in the transformation of the mining industry towards a more efficient and lower-carbon future. Making the switch from an internal combustion engine to an electric motor brings with it several benefits, including no local emissions being produced – in fact, the B‑Air 185-12 saves 140 tons of CO2 emissions, which is equivalent to the yearly exhaust of around 30 passenger cars.

It also drastically reduces downtime and maintenance because the B-Air 185-12's electric motor has far fewer moving (and therefore wearing) parts compared to a diesel engine compressor, it only needs service every 500 hours, as opposed to 2.000 hours for a diesel engine unit. Meanwhile, the battery pack is protected in a triple enclosure, and is liquid-cooled to maximize performance.

The state-of-the-art variable speed drive (VSD) and its magnet motor automatically adjusts motor speed to meet real-time air demand, increasing energy efficiency by up to 70 %.

Like all Atlas Copco portable air compressors, the B-Air has undergone a rigorous testing process, proving that it performs optimally even in the most extreme climatic conditions: from +45°C to -25°C.

Relying on battery-based energy storage systems (ESS) provides mining companies with full control over their temporary power applications, by optimizing energy generation, distribution and consumption. Atlas Copco’s energy storage systems, comprising the ZBP and ZBC ranges, are fit for installations in remote and hard-to-access locations – often the case in quarries and underground mines. These units are ideal for applications with a high energy demand and variable load profiles, boosting the grid available when it is limited, and accounting for both low loads and peaks.

This innovative portfolio of Lithium-ion ESS can operate as standalone or synchronized, serving as the heart of decentralized hybrid systems with multiple energy inputs, such as power generators and renewable energies. Moreover, with the development of mobile solar plants and their integration into the mining industry, energy storage systems will play a crucial role in storing and distributing this renewable energy to sustainably power onsite operations. These battery-based units help mining companies deploy flexible, reliable power while meeting regulations and cutting costs – leading the industry’s transition toward portable and sustainable energy solutions.

Although traditionally diesel-driven light towers have been used to illuminate mining sites, increasing the working day and ensuring safe conditions, more energy-efficient alternatives have been developed in recent years. Electric and solar light towers can eliminate fuel consumption, enabling operators to benefit from cost-cutting solutions, that adhere to noise, light and CO2 emission regulations.

In adherence to international regulations, Atlas Copco assumes responsibility for the batteries in its B-Air 185-12 compressors, its energy storage system portfolio and its solar and hybrid light towers, once they reach the end of their life cycle. The process begins with the collection of spent lithium-ion batteries, which are temporarily stored safely and securely. This step is crucial for ensuring the proper handling and segregation of the batteries based on their condition and type. Atlas Copco then collaborates with a specialized recycling company that possesses the necessary expertise and equipment to recycle Li-ion batteries efficiently and safely.

After a certain time, the batteries are disassembled, and their components are made available for sale. This not only complies with environmental regulations but also offers economic benefits, by generating revenue and reducing waste. The batteries used in Atlas Copco products are designed with circular economy in mind; and to this end, through the process of remanufacturing, they can also be granted a second life. Even with a certain degree of degradation, the batteries can be repurposed for less demanding applications, such as household power supply systems. This practice of utilizing 'second life' batteries contributes significantly to reducing electronic waste and environmental impact. Despite their reduced capacity, these repurposed batteries can still offer substantial performance, potentially extending up to four years.