US manufacturer Wabtec unveiled the first FLXdrive battery locomotive at its design and development centre in Erie, Pennsylvania, on October 31.

The launch customer for what Wabtec says is the world’s first 100% battery-powered heavy-haul locomotive for mainline duties is Australian iron ore mining company Roy Hill, owned by Hancock Prospecting.

Roy Hill currently operates four Wabtec ES44ACi Evolution Series diesel-electric locomotives to haul trains that are typically 2.7km long and carry over 33,000 tonnes of iron ore. The FLXdrive will operate in multiple with the ES44Aci locomotives, its batteries recharging while deployed on the mainline using current produced by regenerative braking.

The FLXdrive battery-electric locomotive has an energy capacity of 7MWh, and is expected to produce a double-digit percentage reduction in fuel costs and emissions per train.

The new locomotive also features a battery thermal management system using liquid cooling to ensure reliable operation in temperatures of up to 55°C in the Pilbara region of Western Australia.

Once Wabtec completes final battery installation and track testing, the new locomotive will begin its 17,000km journey in 2024 for delivery to Roy Hill.

“This FLXdrive locomotive represents a major step in the journey to a low-to-zero-emission future in the rail industry,” says Wabtec president and CEO, Mr Rafael Santana.

“Roy Hill is an ideal customer to partner with given their leadership and excellent operational record.”

“The FLXdrive locomotive represents not only a first for the Pilbara, but a first for the mining industry,” says Mr Gerhard Veldsman, CEO of Hancock Prospecting Group Operations.

“By using regenerative braking, it will charge its battery on the 344km downhill run from our mine to our port facility and use that stored energy to return to the mine.

“This will not only enable us to realise energy efficiencies but also lower operating costs.”

An in-depth feature on decarbonising heavy-haul operations appeared in the October issue of IRJ.

For detailed data on locomotive orders worldwide, subscribe to IRJ Pro.