Simulation study comparing battery swapping to fast charging for electric underground mine haul trucks

To prepare for the electrification of a haul truck operation in a Canadian underground environment, battery swapping and fast charging were virtually compared for an eight-truck fleet, considering productivity, durability, fleet logistics, and total power requirements. A haul truck with a 42-t capacity was simulated. Duty cycles prescribed battery activity, consisting of stationary, driving, and recharging phases. A thermally coupled equivalent circuit model and battery degradation model were used. A parametric study considered fast charging versus pack swapping, pack capacity, route distances, and battery-to-truck ratios for swapping, producing complex output. For durability, larger pack sizes, lower charging power, short routes, and high battery ratios increased battery lifetimes. Energy consumption ranged from 12 to 23 kWh/km. Swapping required from 5% to 27% less energy per km compared to fast charging. For fast charging, one battery lasted from 1.5 to 4 years to 60% state of health, while for swap scenarios, two batteries lasted from 1.5 to 7 years. Compared to diesel, electric trucks had 90% productivity but required less than one-third of the energy. The tracking of battery health in a comprehensive fleet context for two electrification modalities is entirely novel. A deeper techno-economic assessment is a next step.