Inside Fortescue’s Fossil Fuel-Free Rail Transformation

Fortescue is transforming its iron ore supply chain through the deployment of battery-electric locomotives across its Pilbara rail network, marking a significant shift in how mining logistics can operate without fossil fuels.

The company's approach to decarbonising its 760km rail network demonstrates how large-scale supply chain operations can transition to renewable power while maintaining the reliability required to move more than 190 million tonnes of iron ore annually.

The commissioning of two battery-electric locomotives, delivered by Progress Rail, could reduce Fortescue's diesel consumption by approximately one million litres each year. Each locomotive features a 14.5 MWh battery capacity, with the ability to recover between 40% to 60% of energy through regenerative braking, converting kinetic energy into electrical energy that can be stored and reused.

This transition is fundamental to achieving absolute zero emissions.

"Real Zero is about transforming the way we power our assets, move our materials and run our operations, not offsetting emissions but eliminating them," explains Dino Otranto, Chief Executive Officer of Fortescue Metals and Operations.

Powering sustainable logistics operations

The renewable power for these locomotives will be supplied through Fortescue's Pilbara Energy Connect programme, which has already constructed more than 480km of high-voltage transmission lines. This infrastructure physically links the company's energy assets to its operations and rail network, enabling renewable power to replace diesel and gas in real time across the Pilbara region.

"Decarbonising our rail network is a critical part of that task and the commissioning of these battery-electric locomotives demonstrates that heavy-haul rail can operate reliably without fossil fuels," Dino adds.

Fortescue operates a 100 MW solar farm at North Star Junction, supported by a recently installed 250 MWh battery energy storage system capable of delivering 50 MW of power for up to five hours. This infrastructure is essential for stabilising renewable supply across the company's supply chain operations. 

Reimagining heavy-haul transportation

Fortescue's commitment to Real Zero goes beyond the Net Zero targets adopted by many organisations. The company aims to reach absolute zero emissions across Scope 1 and 2 terrestrial emissions by 2030, fundamentally changing how materials are transported across its operations.

All supply chain, sustainability, Scope 3 and net zero leaders should attend:

• Procurement and Supply Chain LIVE: The Net Zero Summit - QEII Centre, London, March 4-5
• Procurement and Supply Chain LIVE: The US Summit - Navy Pier, Chicago, April 21-22

Co-located with Sustainability LIVE, these events brings together CSCOs, CSOs and senior decision-makers at a moment when sustainability, supply chains and commercial performance are increasingly interconnected.
Tickets can be booked online today for The Net Zero Summit and The US Summit. Group discounts available.

"Our relationship with Fortescue reflects what is possible when two organisations share a commitment to advancing the future of rail," says John Newman, Progress Rail President and Chief Executive Officer.

"We are proud to deliver rail solutions that help our customers meet their toughest challenges."

Optimising energy across networks

Fortescue has integrated its Fortescue Zero Elysia battery intelligence and management software to optimise performance and extend battery life across the network. This technology enables real-time monitoring and control of energy flows across the entire rail system.

The software ensures intelligent energy management by balancing power distribution according to operational demands. This capability is critical for maintaining consistent performance across the network.

"Battery storage is the backbone of a renewable-powered mining system," adds Agustin Pichot, CEO of Growth and Energy at Fortescue.

"By integrating Fortescue Zero's Elysia battery intelligence and management software, we're able to optimise performance, extend battery life and intelligently balance energy across the network in real time. This technology ensures the right power is available at the right time – whether that's supporting rail operations, smoothing solar output or maximising the value of stored energy."

Fortescue's expanding portfolio includes progress on its 190 MW Cloudbreak Solar Farm, alongside 12 electric excavators and one electric drill operational across its Pilbara sites. This growing infrastructure demonstrates how supply chain decarbonisation in heavy industry requires integrated approaches that span transportation, energy generation and materials handling.