1159 DECARBONIZATION IN MINING: EMBEDDED SYSTEM FOR HYDROGEN ADDITION IN MINING HAUL TRUCKS *C.E. Arroyo1, R.L. Figueiredo2 1Department of Mining Engineering, Federal University of Ouro Preto, Brazil, (*Presenting author: carroyo@ufop.edu.br) 2 Mineral Engineering Graduate Program, Federal University of Ouro Preto, Brazil, co-author: robsonlage@ufop.edu.br ABSTRACT The growing global demand for minerals driven by the energy transition and technological development requires the mining industry to increase output while improving environmental performance. In many mining operations, material haulage performed by road trucks adapted to mine conditions represents a major share of diesel consumption and, therefore, direct greenhouse gas (GHG) emissions. This paper presents the development and field evaluation of an embedded system for controlled hydrogen injection in the diesel engine of mine‑haul road trucks, aiming to reduce diesel consumption and associated emissions. The on‑board system generates hydrogen via water electrolysis at 4.5 L/min, operating at 55°C and 25 A, and was tested under real operating conditions. Results show a 10.07% reduction in diesel consumption, corresponding to an estimated annual savings of 7,049 L of diesel per truck. Based on a diesel emission factor of 2.68 kgCO₂/L (IPCC, 2006), this represents an estimated reduction of approximately 19 tCO₂/year per vehicle (direct CO₂ from diesel combustion). In addition, average speed increased by 4.50% and productivity increased by 5.26%, indicating that environmental gains can be achieved without compromising operational performance. The findings support controlled hydrogen injection as a feasible and effective pathway for incremental decarbonization of existing diesel fleets in mining operations, particularly when the electricity used for electrolysis is sourced from renewable generation (green hydrogen). KEYWORDS decarbonization; green hydrogen; diesel engines; on‑board electrolysis; embedded control system; mining haulage 1. INTRODUCTION Mining is a fundamental pillar of the global economy, supplying essential raw materials for industry, infrastructure, and increasingly, for energy‑transition technologies. Demand is rising for both critical minerals such as lithium, copper, nickel, and rare earth elements and traditional commodities such as iron ore, driven by electrification, digitalization, and urbanization. This scenario requires the mining sector not only to expand production capacity but also to do so with greater efficiency, safety, and lower environmental impact. Large‑scale mining operations are energy‑intensive, and material haulage often accounts for one of the largest shares of fossil fuel consumption and, consequently, direct GHG emissions. Mine‑haul road trucks frequently rely on high‑power diesel engines, contributing significantly to the sector’s carbon footprint. Increasing decarbonization pressure from regulators, investors, and society has accelerated the search for solutions that reduce emissions without compromising productivity and competitiveness. In this context, hydrogen supplementation in existing diesel engines has emerged as a promising route for incremental decarbonization. By complementing diesel with hydrogen, combustion can be optimized, diesel consumption can be reduced, and direct emissions can be mitigated especially when hydrogen is produced from renewable electricity (green hydrogen). This work investigates the development and application of an embedded hydrogen generation and injection system in mine‑haul road trucks and evaluates its impacts on fuel
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