Case Summary
| Client Industry | Stone Quarrying and Transportation |
| Application Scenario | High-intensity short-haul heavy-duty truck transport in a crushed stone quarry. |
| Core Product | ELFBULB Power 576V1120Ah EV Lithium Battery System |
| Challenge | High diesel consumption, severe engine wear due to dust, non-compliant noise, and emissions. |
| Result | Over 30% reduction in operational costs, achieving zero emissions, near-silent operation, and energy recovery via downhill runs. |
I. The Core Pain Points in the Quarry: Diesel Burn & Environmental Stress
In quarries, mines, and construction sites, heavy-duty trucks are the backbone of production. Yet, they present major operational challenges:
- Exorbitant Fuel Costs: The continuous cycle of heavy-load uphill and empty-load downhill consumes vast amounts of diesel, making up a significant portion of the Total Operating Cost (TOC).
- Harsh Operating Conditions: Extreme rock dust accelerates wear on traditional diesel engines, leading to high maintenance frequency and costly downtime.
- Noise and Emissions Conflict: Constant engine noise pollutes the environment and conflicts with increasingly strict environmental regulations.
The client opted for a strategic “Diesel-to-Electric” (D2E) conversion, powered entirely by our ELFBULB Power 576V1120Ah EV Lithium Battery System.
II. ELFBULB Power: Tailored Power for Extreme Conditions
To meet the high-torque demand and endure the harsh environment of the quarry, ELFBULB Power delivered a bespoke battery solution:
1. Superior Power Output and Hill-Climbing Capability
We utilized the 576V1120Ah EV Lithium Battery as the core power source. This system features High-C-rate Lithium Iron Phosphate (LFP) cells, boasting high voltage and large capacity, paired with an efficient Liquid Cooling/Heating Thermal Management System specifically designed for heavy-duty trucks. This ensures:
- Instantaneous Torque Burst: The 576V high-voltage platform guarantees the electric drive system can instantly deliver maximum power and torque during startup and heavy uphill climbs, navigating the quarry’s challenging grades far more efficiently than traditional diesel engines.
- Reliable Endurance: The ultra-large capacity of 1120Ah ensures the heavy-duty truck has ample range for high-intensity, multi-cycle short-haul rock transport, meeting round-the-clock operational demands.
- Stable Operation: The battery system maintains an optimal temperature range, ensuring uninterrupted, high-intensity operations regardless of summer heat or winter cold.
2. Unique Energy Recovery: Downhill is Charging Time
The quarry’s unique terrain—frequent downhill runs—means potential energy is often wasted. Our battery system leverages this feature fully:
- High-Efficiency Regenerative Braking: As the truck descends (empty or light-loaded), the drive motor instantly converts into a generator, transforming the vehicle’s kinetic and potential energy back into electricity, which is then fed back into the 576V1120Ah battery pack.
- Efficiency Boost: Through highly efficient energy recovery, each cycle provides an estimated 15% to 25% of supplementary range or charge, substantially reducing charging needs and overall energy consumption.
3. Ultimate Safety and Extended Cycle Life
The ELFBULB Power heavy-duty truck battery pack is engineered to meet the stringent IP67 Dust- and Water-Resistance rating, effectively shielding it from the quarry’s dust, moisture, and intense vibration. Furthermore, the high-quality cells guarantee an ultra-long cycle life of over 6,000 cycles, fully supporting the truck’s 8-10 year operational lifespan and drastically reducing the TCO.
III. Case Results: Efficiency Revolution and Green Mining
Since the deployment of the ELFBULB Power 576V1120Ah EV Lithium Battery System, the truck fleet has achieved transformative operational metrics in the quarry, ushering in a new era of green efficiency:
- 【Significant Economic Benefits】
The electrification project dramatically optimized the client’s energy costs. Compared to conventional diesel trucks, the energy consumption expense of the ELFBULB Power system was reduced by over 30%. Furthermore, due to the simpler nature of the electric drivetrain, which eliminates the high-frequency maintenance associated with traditional engines, maintenance costs for the engine and gearbox were cut by approximately 60%, significantly minimizing vehicle downtime and ensuring production continuity.
- 【Environmental and Workplace Transformation】
The electric trucks achieved zero emissions, completely resolving the exhaust pollution issue and fully aligning with increasingly strict environmental mandates, thereby helping the client realize their “Green Quarry” strategic goals. Crucially, the working environment saw a vast improvement: the operating noise of the electric trucks was reduced to near-ambient levels, drastically mitigating noise pollution, reducing operator hearing fatigue, and significantly boosting workplace comfort and safety within the quarry.
- 【Client Testimonial】
Client Feedback: “The sheer power and endurance of the ELFBULB Power 576V1120Ah battery are impressive. It has not only saved us huge amounts on diesel and maintenance but, more importantly, the trucks now have stronger power uphill and offer a better driving experience. This is the most crucial step in our green quarry strategy.”
