SOLUTIONS — MINING & HEAVY EQUIPMENT
Mining & Heavy Equipment — Hydrogen Retrofit Solutions
Reduce diesel consumption, improve engine performance and lower emissions in heavy-duty mining and off-highway equipment — without replacing machines.
4–15% Diesel Savings
Maximized during high-idle and variable-load cycles typical of excavation and loading.
40–90% PM Reduction
Verified reduction in particulate matter (PM), CO, and HC emissions for cleaner operations.
Rugged & Certified
Vibration-resistant, dust-protected, and compliant with CE, UL, and ISO 9001 standards.
Safety & Durability Standards
Decarbonising Off-Highway Operations Without Machine Replacement
Mining and heavy equipment operate under some of the harshest duty cycles in the world — high idling, variable load, heavy fuel burn and continuous operation. Saarthi’s hydrogen retrofit system helps reduce diesel usage and emissions while improving combustion quality and engine stability.
This solution integrates GreenLabs’ engineering, GreenMentor’s advisory and GreenVision’s real-time verification.
CORE TECHNOLOGY
GreenDrive™ Heavy — Hydrogen Retrofit
A rugged, vibration-resistant, dust-protected hydrogen retrofit system engineered specifically for mining and construction equipment. Our system ensures high reliability and safety in extreme duty cycles.
Key Benefits:
- 4–15% fuel savings (depending on load & idle ratio)
- Reduced soot accumulation leading to longer engine life
- Significant reduction in PM, CO and HC emissions
- Improved combustion stability under heavy load
- Lower black-smoke output and cleaner exhaust
- Verified performance via GreenVision telemetry
Supported Equipment:
Excavators (10–100+ tons)
Rigid Dump Trucks (RDTs)
Articulated Dump Trucks (ADTs)
Front-end loaders
Backhoe loaders
Dozers & graders
Cranes & material handlers
Drilling rigs
Heavy mining site generators
High Fuel Burn + High Idle Time = High Savings Potential
Mining equipment often idles for long durations and works under highly varying load. Hydrogen-enabled cleaner combustion makes idling far more efficient, reducing wasted diesel during transient load periods.
Typical Observations:
- Idle-heavy machines: **5–18% savings**
- Constant-load equipment: **3–15% savings**
- Reduced particulate build-up and cleaner injector performance.
- Lower engine stress under quick load changes.
Cleaner Combustion for Extreme Duty Cycles
The process ensures safety and efficiency, delivering hydrogen on demand to enhance diesel combustion.
Hydrogen Generated On-Demand
Safe, low-pressure H-Oxy electrolyser unit produces gas only when needed. No bulky compressed cylinders required.
Controlled H-Oxy Injection
The system adjusts the hydrogen flow automatically to match the engine’s real-time load, RPM, and duty-cycle patterns.
Cleaner Diesel Combustion
Hydrogen acts as a combustion enhancer, leading to lower soot production, better engine breathing, and stable power delivery.
Real-Time Verification
GreenVision tracks fuel use, idling, CO₂ reduction, and engine health, providing auditable performance data.
Real-World Performance Validated Across Similar Engines
Mining equipment uses high-displacement diesel engines similar to truck or DG engines. Our extensive DG test data and truck telemetry offer accurate performance indicators for heavy machinery.
Emission Reduction (DG Test Equivalent):
- Particulate Matter (PM): **40–90% reduction**
- Hydrocarbons (HC): **Significant reduction**
- Carbon Monoxide (CO): **Significant reduction**
- Black Smoke: **Visibly clearer exhaust**
Fuel Efficiency:
- Idle cycles: **5–18% savings**
- Heavy excavation cycles: **5–15% savings**
- Transport cycles (dumpers): **4–12% savings**
Designed for Rugged, High-Demand Environments
Our GreenDrive™ Heavy system thrives where diesel engines are pushed to their limit, providing stability and savings in the toughest conditions.
Where This Solution Works:
Two Deployment Options to Fit Any Operation
Choose the financing model that best suits your capital expenditure strategy and operational scale.
A. CapEx Purchase
The traditional route for full asset ownership and control over the long term.
- Own the system outright (Asset on your balance sheet)
- Full installation & commissioning included
- Comprehensive warranty and technical support
- Integrated GreenVision dashboard for monitoring
B. DaaS — Decarbonisation-as-a-Service (Zero CapEx)
Ideal for mine operators with large fleets seeking immediate savings without upfront investment.
- **No upfront investment** required
- Monthly fee is **less than** monthly fuel savings (pay-for-performance model)
- Saarthi handles all system maintenance & spares
- Savings are verified through GreenVision platform
- Scales easily across large fleets and multiple sites
Engineered for Dust, Heat, Vibration & Harsh Conditions
Safety and durability are non-negotiable. The GreenDrive™ Heavy system is built to withstand the physical demands of any mining or construction environment.
Features & Safeguards:
Certifications:
CE • UL • ROHS • EMC • ISO 9001
Compatible With Most Heavy Equipment Engines
Our system is engine-agnostic and designed for quick, non-invasive integration with the most common brands found in mining and construction fleets globally.
Supported Engine Brands:
Caterpillar
Komatsu
Volvo
JCB
Hitachi
Tata Hitachi
SANY
Doosan
Bobcat
Scania
Ashok Leyland
Cummins
Kirloskar
Installation Process:
- **Quick turn-around:** Typically 6–10 hours per machine
- Minimal operational downtime (often during off-hours or scheduled breaks)
- On-site installation by Saarthi-certified technicians
- GreenVision monitoring enabled post-installation for immediate verification
The End-to-End Decarbonisation Flow for Mining
Saarthi provides a complete solution, from financial modeling to deployment and verifiable long-term reporting.
GreenMentor
Assess duty cycles, idle patterns, and calculate site-specific ROI and CO₂ reduction potential.
GreenLabs
Install the custom-engineered GreenDrive™ Heavy Retrofit System on your fleet.
GreenVision
Verify fuel savings, track engine performance, and provide auditable ESG compliance data in real-time.
Ready to Improve Fuel Efficiency Across Your Heavy Equipment?
Share your equipment details, idle ratios and monthly diesel usage for a custom savings estimate.