BHP and Wabtec trial 4,400 hp battery-electric locomotives

BHP has been operating two 4,400 horsepower battery-electric locomotives for nearly a year at its Jimblebar iron ore mine in Australia. The mining giant now believes the Wabtec FLXDrive units are ready for wider use after this dedicated track trial.

According to a new video released by the company, the locomotives arrived at Port Hedland in November. They were immediately put to work on BHP's rail routes between the Jimblebar mine and its Port Hedland operations in the Pilbara region.

Peter Thomas, Wabtec's Regional Senior Vice President for ANZ & SEA, commented on the project. The Pilbara has always been a place of big ambition, and these locomotives represent the kind of innovation that is needed to keep the region firing, he said. "Wabtec is proud to partner with BHP on this important step toward decarbonising rail operations."

Locomotive specifications and operation

While most heavy-haul trains use diesel engines to generate electricity for their drive motors, the FLXDrive locomotives draw power exclusively from onboard batteries. Each locomotive carries a massive 7 MWh battery pack.

The system incorporates advanced regenerative braking technology. This captures energy during downhill braking and feeds it back into the battery. On some long downhill runs loaded with ore, the locomotives could theoretically generate enough power to send the empty train back uphill for another load.

Expanding the trial program

BHP has announced plans to add two more battery-electric locomotives to its Pilbara operations for extended trials. The company stated that two further locomotives from a different supplier, Progress Rail, were delivered to Perth. They are scheduled for transport to Port Hedland for commissioning and testing.

This expansion will create a unique testing environment. BHP expects to be one of the first mining companies globally to conduct side-by-side evaluations of battery-electric heavy haul locomotive technologies from two different suppliers within the same operating conditions.

The company's official statement outlined the timeline: In FY2026, we commenced commissioning of two purpose-built Wabtec FLXdrive heavy-haul battery-electric locomotives in Port Hedland. Two further locomotives from Progress Rail were delivered to Perth in FY2026 and to be transported to Port Hedland for commissioning and testing in FY2027.

The principle of regenerative haulage

Using gravity to recharge heavily-laden vehicles on downhill runs is not a new concept in mining. The practice has been successfully implemented in various topographies since at least 2017, primarily with large dump trucks. Applying this principle to a rail system, combined with traction braking and large-scale battery storage, represents a logical next step for industrial electrification.

The successful trial in one of the world's most demanding environments suggests significant potential for fuel savings and emissions reduction in heavy industry. The report from Electrek, which first covered the locomotives in August, speculates that adding battery-electric rail cars to such a system could further enhance its efficiency.