Redesigning for decarbonisation: the shift towards electrified hydraulic power

Australia’s industrial sector is under increasing pressure to reduce emissions while maintaining productivity and reliability. Rising energy costs, tighter decarbonisation policies and growing demand for sustainable operations are driving companies to rethink how equipment and power systems are designed and operated. Across the mining, oil and gas, manufacturing and infrastructure sectors, electrification and energy-efficient system design are emerging as practical pathways towards decarbonisation.

For many industrial sites, particularly in remote and off-grid environments, diesel-powered systems have traditionally been the only viable option. However, advances in electrified drive technology, battery storage and smarter hydraulic system engineering are now creating opportunities to complement existing diesel infrastructure, helping industrial operators reduce fuel consumption, maintenance requirements and carbon emissions while maintaining reliability.

One area gaining attention is the electrification of hydraulic power systems. Conventional diesel-driven hydraulic power units (HPUs) are widely used across heavy industries, but they often operate inefficiently, particularly in intermittent-duty applications where engines remain running while demand fluctuates. This leads to unnecessary fuel burn, increased servicing requirements and higher operating costs.

Through system engineering and redesign, these systems can be optimised using a combination of electric drive technologies, hybrid architectures and energy-efficient solutions that improve overall efficiency while supporting decarbonisation objectives. HYDAC Australia has been working with customers to develop electrified hydraulic systems using advanced drive technologies such as ENGIRO motors and integrated system solutions designed for industrial applications.

A recent project delivered for an oil and gas customer in Queensland demonstrated the benefits of this approach. The customer operated diesel-driven hydraulic equipment in a remote mining area with limited infrastructure and no access to grid power. The hydraulic system was required intermittently to erect and operate machinery critical to site operations.

HYDAC engineered and integrated an electrified hydraulic solution using an ENGIRO efficiency drive with interior permanent magnet (IPM) technology to complement the existing site infrastructure. The system reduced reliance on diesel operation while maintaining the reliability and flexibility required for remote industrial applications.

The result was a more reliable and efficient hydraulic system with reduced servicing requirements, lower fuel costs and reduced emissions. In remote applications where maintenance access can be difficult and expensive, reducing engine servicing intervals also delivered significant operational benefits.

Battery energy storage is also emerging as a practical solution for reducing reliance on standby diesel generators. Across many remote industrial and mining sites, generators are commonly left in standby mode to ensure sufficient backup power is available to start critical equipment and applications when required. While effective, this approach often results in unnecessary fuel consumption and ongoing engine maintenance, even during periods of low demand.

Battery-based backup systems can provide a complementary or hybrid solution alongside existing diesel infrastructure. By integrating battery storage with existing generator infrastructure, sites can reduce generator runtime, lower fuel consumption and minimise emissions while still maintaining the reliability and backup capability required for critical operations. In some applications, battery systems can also improve system responsiveness and energy efficiency by supplying instant power during startup or peak demand events.

As industries continue progressing towards lower-emission operations, the focus is shifting towards smarter system integration, where existing infrastructure can be enhanced through more energy-efficient technologies and hybrid solutions. Smarter system engineering, energy-efficient drive technologies and integrated electrified solutions are becoming essential tools for improving productivity while supporting long-term sustainability goals.

For Australian industry, decarbonisation is no longer only about meeting policy requirements, it is increasingly becoming an operational and commercial advantage. Companies that invest in higher-efficiency systems today are positioning themselves to reduce operating costs, improve reliability and prepare for the future energy landscape.

Image credit: iStock.com/Shutthiphong Chandaeng