Introduction
This project marked one of the earliest large-scale demonstrations of regenerative braking for mining haul trucks. Commissioned by Shenhua Energy and delivered by Alta, the Komatsu 930E was modified to enable hybrid energy recovery, forming the foundation for future hybrid haul truck development.
The Regenerative Braking System installed on the Komatsu 930E
Alta's Scope of Work
Alta led the development, supply and integration of the following major systems and components:
Technology Snapshot
The system captures and stores braking energy to improve efficiency on downhill runs and during deceleration, reducing fuel consumption and emissions without altering haul cycle performance.
What is Regenerative Braking?
Regenerative braking converts a vehicle’s kinetic energy into electrical energy during deceleration. Instead of being lost as heat through friction brakes, this energy is captured and stored in onboard batteries for reuse during acceleration or auxiliary functions. In mining applications, where heavy trucks regularly descend loaded grades, the energy recovery potential is substantial, making regenerative braking one of the most immediate steps toward lower-emission operations.
Trial
Over a two-month trial period, the hybrid module was tested on a coal-hauling Komatsu 930E under standard operating conditions. The truck maintained all functionality (including autonomous systems) while the module’s 22 kWh limit ensured the results reflected a conservative measure of its real-world fuel-saving potential.
Heavy Load Uphill Time
11 Mins
Empty Load Downhill Time
6 Mins
Total Trip Time Including Loading & Unloading
28 Mins
One Way Trip Distance
5300m
Max Slope Gradient
8%
Results
A two-month operational trial confirmed the technical feasibility of the hybrid regeneration module. Even with the test battery limited to 22 kWh, the system demonstrated measurable fuel and emission reductions while maintaining full operational capability, including autonomous driving functions. The project validated regenerative braking as a low-cost, high-impact decarbonisation pathway for large mining fleets.
Outcome & Significance
The two-month trial served as a proof of concept for Alta’s regenerative braking technology, confirming its compatibility with large-scale mining operations and autonomous systems. While the module’s fuel savings were modest due to a limited 22 kWh configuration, the real achievement lay in demonstrating stable hybrid functionality under real-world conditions. The Komatsu 930E project established a critical foundation for future developments in full-scale hybrid and electric haul trucks, validating Alta’s approach to modular, scalable electrification in heavy mining.