Cummins has commissioned a new alcohol fuel test cell as part of its joint project with Komatsu and Vale.
The commissioning marks a significant milestone in its joint project to develop an ethanol/diesel-powered surface mining haul truck aimed at reducing greenhouse gas emissions.
Announced in July 2024, the dual fuel program aims to retrofit existing diesel engines in Komatsu haul trucks to operate on both ethanol and diesel. The modified 230-ton to 290-ton haul trucks will be able to use up to 70 per cent ethanol, potentially lowering carbon dioxide emissions by as much as 70 per cent.
“Ethanol/methanol diesel dual fuel systems offer significant benefits to the mining industry, including the realization of up to 70 per cent decarbonization – lowering carbon dioxide, nitrogen oxides and particulate matter – while continuing to meet comparable productivity and performance requirements,” said Luke Mosier, Cummins Innovation Program Leader. “More than that, miners who utilize alternative fuels can utilize their existing infrastructure and leverage their current fleet, facilities and personnel.”
When operational, the haul trucks would be the first vehicles of this size to run on ethanol in the tank.
“At Cummins, we’re committed to advancing practical, sustainable solutions that support the energy transition,” said Gbile Adewunmi, Vice President of Industrial Markets – Power Systems Business. “Our work in enabling low-carbon fuel pathways — like ethanol dual-fuel technology — demonstrates our dedication to reducing emissions while delivering reliable performance for our customers and partners.”
The Cummins QSK60 Engine testing is expected to run until 2026 before field tests begin at Komatsu’s facilities.
“Our ongoing dual fuel project, developed in close collaboration with Cummins and utilizing a blend of ethanol and diesel, is an important bridge technology aimed at supporting Vale’s near-term decarbonization goals,” said Dan Funcannon, Senior Vice President, Surface Haulage, Komatsu. “This initiative reflects our shared commitment to practical, scalable solutions that advance sustainable mining. The launch of the dedicated test cell is an exciting milestone as we continue to develop and deploy low-carbon technologies for the future of haulage.”
The Brazil-based Vale is one of the world’s largest producers of iron ore and nickel and a major copper producer. The company has set a target of reducing its scope 1 and 2 greenhouse gas emissions by 33 per cent by 2030. Among mine equipment, the haul truck is one of the biggest consumers of diesel. Ethanol is already a widely adopted fuel in Brazil, with an established supply network.
RELATED: KGM and SMS Equipment debut the first PC9000 in Canada
“We continue to make progress on our decarbonization projects, reinforcing Vale’s commitment to this issue,” said Carlos Medeiros, Vale’s Executive Vice President of Operations.
“Ethanol is a priority input to achieve our goal of reducing the use of diesel in our operations while keeping reliability and operational excellence.”
The new advanced low carbon fuel test cells at Cummins’ Seymour, Indiana Engine Plant showcase continued investments in fundamental research facilities and internal capabilities designed to support its decarbonization programs and drive advancements in carbon-reducing technology and innovations that move the industry closer toward carbon neutral power systems.
“We are excited to bring this dual fuel test cell online, as part of our Dual Fuel Engine Development Program that reinforces our commitment to collaborating with OEMs and mining companies in the development and testing of bridge technologies,” Adewunmi said.
“By leveraging advanced technologies like low carbon test cells and our versatile test asset for power electronics, batteries, fuel cells and hybrid systems, Cummins remains at the forefront of guiding miners toward carbon reduction both now and in the future.”
Cummins low carbon fuel test cells accommodate a wide range of high horsepower engines — from 38-litre to 95-litre fuel capacity — and ensure seamless transition of a variety of alternate fuel types for varied testing scenarios.
The specialized facilities also maintain a high precision environment to deliver accurate emissions with reliable data and provide safe storage conditions to prevent contamination and maintain fuel quality
