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Lithium-ion electrification of mining equipment: Explosion-proof safety and extreme environment adaptability solutions
2025-12-09
Mines, particularly underground operations, present the most demanding environment for power equipment. Traditional internal combustion engines and lead-acid batteries can no longer meet the comprehensive requirements for safety, environmental sustainability, and efficiency demanded by modern surface and underground mining. Since its inaugural mining-grade lithium-ion battery gained certification in 2013, Frey has remained dedicated to providing intrinsically safe, high-performance lithium-ion power solutions for global surface and underground mining operations.
01 The dual challenges of mining and underground power systems: safety risks and environmental extremes
Explosion-proof safety: the lifeline in gas and coal dust environments
"Explosive gas environments" in underground coal mines, characterised by methane (CH₄) and coal dust, mandate that all electrical equipment must possess Class I explosion-proof ratings. Any electrical spark or high-temperature surface could trigger catastrophic accidents.
「Hydrogen hazards in conventional batteries」Lead-acid batteries inevitably release hydrogen during charging, forming explosive gas mixtures within confined underground spaces – a significant safety hazard.
「Equipment compatibility requirements」Battery systems must comply with mining explosion-proof standards such as "Ex db l Mb" and undergo deep integration with equipment including electric locomotives, monorail cranes, and rubber-tyred vehicles.
Extreme environments: the ultimate test for powertrain systems
Underground environments exhibit extreme temperature variations, with certain operating conditions persisting at prolonged high or low temperatures (e.g., cold storage facilities, high-temperature mining faces). This necessitates batteries capable of stable operation within a temperature range of -20°C to 55°C (standard type) or even -20°C to 60°C (enhanced type).
High humidity and water spray conditions, where relative humidity frequently exceeds 90% and scenarios such as water spraying or spray coating are present, necessitate battery protection ratings of IP54, IP65, or even IP67.
「Severe Vibration and Impact」 Underground transport conditions are complex, with continuous impact and vibration accompanying the operation of equipment such as electric locomotives and loaders. This places extremely high demands on the mechanical structural strength of batteries.
02 Frey Solutions: Full-Stack Technology from Intrinsic Safety to Intelligent Early Warning
Frey is one of the first enterprises in the nation to obtain underground explosion-proof certification for lithium-ion batteries. Its products have been certified by the National Centre for Safety Marking of Mining Products and comply with safety access requirements for coal mines, non-coal mines, and underground operations.
Utilising our proprietary LFL3-60, LFL4-100, and LFL1-230 series coal mine safety (MA) certified lithium battery cells, their thermal stability significantly surpasses other systems, eliminating thermal runaway risks at source. The cell casings employ aluminium alloy construction with high-strength structural design, meeting stringent mechanical requirements for both explosion-proof (e.g., DXBL series) and general-purpose (DXL series) products.
System-level safety design, explosion-proof construction and intelligent BMS
The flameproof battery enclosure is fabricated from high-strength steel plate welded construction, incorporating specialised flameproof surfaces and secure fastening mechanisms to ensure any internal sparks or explosions remain entirely contained within the enclosure. This design complies with the Ex db I Mb explosion-proof standard.
「Full Temperature Range Adaptability」 Charging: 0°C to 55°C (Standard Type) / 0°C to 45°C (Select Models) Discharging: -20°C to 55°C / -20°C to 60°C Storage: 20°C to 45°C (Humidity 25% to 65%)
「Multi-layered Electrical Protection」 The BMS implements multiple hardware protections including overcharge, over-discharge, overcurrent, short-circuit, and temperature safeguards. Instantaneous discharge current capability reaches twice the continuous current rating (e.g., 230A vs 115A), meeting peak power demands such as electric locomotive start-up.
Cloud-based intelligent alerts, proactive safety through proprietary EMS and AI algorithms
Frey's independently developed SP300 high-performance EMS (Energy Management System) integrates cloud computing to establish a unified cloud-edge active safety architecture.
Real-time monitoring and analysis of vast amounts of battery operational data, utilising AI algorithms to accurately predict battery health status (SOH) and potential risks, transforming passive protection into proactive alerts. The EMS features a 792MHz CPU and 4Gb storage, supports 41 interfaces, and operates stably within temperatures ranging from 40°C to 60°C, enabling rapid local data processing and decision-making.
The cloud platform delivers end-to-end services spanning "data monitoring, status queries, and alarm alerts" through to "long-term optimisation and intelligent operations and maintenance", significantly extending power supply lifespan and enhancing the reliability of emergency power protection.
03 Product Matrix and Contextual Applications
Frey offers a comprehensive product portfolio covering both coal and non-coal mines, with voltage platforms ranging from 51.2V to 320V and capacities extending from 9.5Ah to 500Ah.
Explosion-proof charging unit accessories
We supply explosion-proof chargers including models such as C.L1-300000/400A, delivering an output power of up to 30kW. These units support a wide voltage range (175VDC-750VDC) with an efficiency rating of ≥94%, featuring comprehensive input and output protection for seamless integration with battery systems.
04 Core Values: From Security Compliance to Operational Excellence
Safety Value → Creating an Intrinsically Safe Working Environment
Eliminating Hydrogen Explosion Risks: Lithium-ion battery charging produces no hydrogen gas, fundamentally resolving the inherent safety hazards of lead-acid batteries.
Preventing Exhaust Pollution: Electrified equipment achieves zero emissions underground, significantly improving air quality and protecting miners' health.
Proactive Safety Alerts: Cloud-based EMS utilises big data to detect anomalies early, preventing accidents before they occur
Economic value → Reducing total lifetime costs
Reduced energy costs: Electricity charges are significantly lower than diesel expenses, coupled with superior energy conversion efficiency.
Minimal maintenance requirements: Lithium batteries require no periodic water topping up or balancing maintenance like lead-acid batteries, achieving near-maintenance-free operation.
Extended service life: Lithium iron phosphate batteries boast a long cycle life matching equipment lifespans, reducing replacement frequency and capital expenditure.
Enhanced operational availability: Supports rapid charging within 2-3 hours, significantly increasing equipment utilisation compared to lead-acid batteries requiring 8-12 hours to charge.
Management Value → Empowering Mine Digitalisation and Intelligence
Transparent management: Real-time tracking of each device and battery's location, charge level, and health status via the cloud platform.
Predictive maintenance: Data-driven scheduling of maintenance plans to minimise unplanned downtime.
Optimised dispatch: Scientific allocation of devices based on charge data to enhance overall operational efficiency.
Conclusion
The transition to lithium-ion batteries for mining and underground equipment represents a profound transformation centred on safety and driven by efficiency.
Frey, with its nationally certified explosion-proof credentials, fully self-developed battery and EMS technologies, and comprehensive product portfolio spanning all operational scenarios, not only delivers compliant and reliable power solutions but also facilitates the digital transformation of mining and underground operations. This shift moves from passive safety to proactive safety, and from experience-based management to data-driven decision-making, all enabled by cloud-based intelligence.
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