Australia’s first purpose-built battery-electric locomotives have arrived in the Pilbara, marking a major step toward decarbonising heavy-haul mining rail.
Late-2025 saw Australia welcome its first purpose-built battery-electric locomotives with BHP paving the path in Western Australia’s Pilbara region.
The arrival represents a sign of the major steps forward for heavy-haul rail innovation through a combination of cutting-edge technology and a clear focus on reducing emissions and improving efficiency.
The locomotives were delivered in partnership with Wabtec, with the two fully battery-powered units to be trialled in BHP’s iron ore rail routes connecting Pilbara mines to Port Hedland.
BHP Western Australia Iron Ore (WAIO) asset president Tim Day said it was incredible to see the battery-electric locomotives arrive in Port Hedland, referring to them as the culmination of years of planning, problem-solving and partnership.
“It marks the beginning of an important trial to understand how this technology can help us reduce diesel use, lower associated operational greenhouse gas emissions, and improve efficiency across our rail network,” Day said.
Built to withstand extreme heat and rugged terrain, these locomotives feature a seven-megawatt-hour battery system and regenerative braking, which captures energy during downhill runs and feeds it back into the battery.
Day said that the Pilbara has always been a place of big ambition, and the locomotives are a symbol of the kind of innovation required to keep the region going.
That sentiment was echoed by Wabtec regional senior vice president for ANZ and SEA Peter Thomas, who said the battery-electric locomotives’ arrival marked a significant milestone for innovation in the region.
“Wabtec is proud to partner with BHP on this important step towards decarbonising rail operations,” he said.
“These FLXDrive locomotives are purpose-built to perform in one of the world’s most demanding environments, combining advanced battery technology and regenerative braking to deliver high efficiency and lower emissions.”
This endeavour to cut emissions and improve productivity has been in the works for some time, with BHP ordering its first four battery-electric locomotives for the WAIO network in 2022, alongside its partnership with Rio Tinto on electric haul trucks in 2024, representing steps to achieve its net-zero goal by 2050.
For BHP’s operations, this new initiative is a key piece in its larger decarbonisation puzzle. In 2022, the Big Australian estimated that a full fleet transition to battery-electric locomotives would cut its WA iron ore diesel-related carbon emissions by roughly 30 per cent annually.
Considering the fact BHP leads a fleet of more than 180 locomotives in the Pilbara, this would prove to be a substantial decrease, with this diesel reduction not only slashing carbon emissions but also other pollutants and fuel costs.
Beyond emissions, however, this trial will be an indicator of battery-electric locomotives’ operational viability and cost-effectiveness, considering diesel’s status is so tied to larger operating expenses.
Powering the Pilbara
BHP is not alone in adopting battery-electric rail.
Rio Tinto purchased its first battery-electric locomotives in 2022, with its managing director of port, rail and core services Richard Cohen highlighting the dual purpose of the technology.
“Battery-electric locomotives offer significant potential for emissions reduction in the near term as we seek to reduce out Scope 1 and 2 carbon emissions in the Pilbara by 50 per cent by 2030,” he said at the time.
Hancock Prospecting subsidiary Roy Hill also partnered with Wabtec to introduce the first FLXDrive heavy-haul locomotive in 2023.
Hancock Prospecting group operations chief executive officer Gerhard Veldsman explained the benefits of regenerative braking.
“It will use that stored energy to return to the mine, starting the cycle all over again,” he said. “This will not only enable us to realise energy efficiencies but also lower operating costs.”
Achieving these companies’ goals in the region hinges on the performance and effectiveness of Wabtec’s FLXDrive, a component in which the company is very confident, saying it is “designed to replace” diesel locomotives.
Regenerative braking is the key feature within the FLXDrive, especially in the Pilbara, where loaded trains travel downhill to port. That means each locomotive is able to harvest considerable energy per trip.
That stored energy can then be used to power the locomotive when it is heading back to the mine, reducing the need to pull power from the grid or the on-board diesel.
The arrival and trial of battery-electric locomotives in the Pilbara, led by BHP and supported by Rio Tinto and Roy Hill, represents a turning point for heavy-haul rail in Australia.
While challenges no doubt remain around infrastructure and fleet scale, the momentum behind battery-electric locomotives is unmistakable.
These units promise reduced diesel consumption, lower emissions, quieter operation and the potential for reduced maintenance costs. They also demonstrate that resources sectors such as iron ore can lead on innovation while tackling climate challenges.
For the Pilbara, where iron ore rail networks are the arteries of Australia’s largest mining operations, battery-electric locomotives represent a future-facing step.
As BHP’s trial progresses, the wider mining industry will watch closely, with successful integration potentially opening the door for adoption across other commodities and regions.
BHP’s milestone is a signal that Australian mining rail is ready to move into a low-emissions future without compromising performance.
Battery-electric locomotives at a glance:
- Battery capacity – seven megawatt-hours
- Power source –fully battery-powered, no diesel engine required for trial operations
- Key feature – regenerative braking captures energy on downhill runs to recharge batteries
- Trial route – BHP’s WAIO iron ore network, Pilbara mines to Port Hedland
- Expected benefits – lower diesel use, reduced emissions, quieter operation, reduced maintenance costs
- Fleet context – BHP operates more than 180 locomotives in the Pilbara; full transition could cut diesel-related emissions by 30 per cent per year