Fortescue Zero: Advanced Engineering Powering the Future of Industrial Decarbonisation

Fortescue Zero is a green technology and advanced engineering business focused on helping major industries reduce their dependence on fossil fuels. Headquartered in Kidlington, Oxfordshire, the company develops battery systems, electrified powertrains, high-power charging technology, intelligent software, autonomous fleet solutions and engineering services. Its technology is designed for demanding real-world environments where performance, reliability and efficiency are essential.

The business combines experience from motorsport with the requirements of heavy industry. This engineering background allows it to work across mining, automotive, construction, infrastructure, motorsport and stationary energy storage. Fortescue Zero is part of the wider Fortescue group and plays an important role in its long-term effort to reduce diesel use and operational emissions. Its technology is also developed for organisations outside the Fortescue group, giving the company a wider commercial purpose.

Fortescue Zero and Its Engineering Background

Fortescue Zero has strong roots in Williams Advanced Engineering, a specialist engineering company created from the technical environment connected with Williams Formula One. Williams Advanced Engineering was established to take expertise developed through elite motorsport and apply it to industries outside racing. The business became known for batteries, electrification, lightweight engineering, energy systems and advanced technical development.

The current UK company was incorporated in March 2012 as Williams Advanced Engineering Limited. Fortescue acquired the business in 2022 for £164 million, bringing specialist battery and electrification expertise directly into the group. This acquisition was important because Fortescue was already planning to reduce the use of diesel across its large mining operations and needed advanced technology capable of working in difficult industrial conditions.

The company later changed its name to WAE Technologies Limited before becoming Fortescue Zero Limited in June 2024. The new identity reflected its growing role within Fortescue and its stronger focus on zero-emission industrial technology.

From Motorsport Engineering to Fortescue Zero

Motorsport continues to influence the company’s engineering culture. Racing requires batteries and electrical systems to perform under extreme pressure while maintaining precise temperature control, rapid power delivery and high reliability. These qualities are equally important in mining equipment, electric vehicles, construction machinery and large charging systems.

Fortescue Zero uses this experience to solve industrial challenges where ordinary electrification technology may not be sufficient. Heavy machinery must operate for long periods, carry large loads and withstand dust, heat, vibration and rough terrain. Developing electric systems for these environments demands a combination of battery science, software, mechanical engineering and power electronics.

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Fortescue Zero Headquarters and UK Operations

Fortescue Zero is headquartered in Kidlington, Oxfordshire. Its registered office is at The Fortescue Building, The Boulevard, Kidlington, OX5 1GB. Oxfordshire remains an important centre for its research, engineering and technology development.

The company also strengthened its testing capability through facilities in Banbury. These operations support battery development, prototype testing, electrical systems, technical validation and engineering integration. This gives its engineers the ability to test technologies before they are introduced into large industrial programmes.

The company originally had broader ambitions for large-scale manufacturing in Britain. Its strategy has since changed, with greater attention now placed on research and development, advanced software, intellectual property, engineering design and systems integration. Large manufacturing partners can provide production scale while Fortescue Zero concentrates on areas where its technical expertise offers greater value.

Fortescue Zero Workforce

The business expanded considerably after Fortescue acquired Williams Advanced Engineering. Its workforce grew as new battery, powertrain and charging programmes were developed. Restructuring during 2025 and 2026 later reduced the size of the UK operation, with recent figures placing the workforce at roughly 600 people.

The company therefore remains a major engineering employer in Britain, but its workforce is increasingly centred on research, technology, software and advanced engineering rather than mass manufacturing. This shift reflects Fortescue’s wider strategy of combining specialist internal expertise with the manufacturing capability of global industrial partners.

Fortescue Zero and the Real Zero Strategy

Fortescue uses the term Real Zero for its ambition to remove operational emissions rather than depending mainly on carbon offsets. Fortescue Zero provides many of the technologies required to turn that ambition into practical industrial systems.

Fortescue has stated that technology developed by the business could help eliminate 630 million litres of diesel and 2.4 million tonnes of carbon dioxide equivalent while generating hundreds of millions of dollars in annual savings. These targets demonstrate the scale of the challenge because mining companies operate large fleets of trucks, trains, dozers, graders and other machines that traditionally depend heavily on diesel.

Reducing this fuel demand requires much more than replacing a combustion engine with an electric motor. Companies must also consider batteries, charging infrastructure, energy supply, operating schedules, route planning, software and fleet management. Fortescue Zero works across these connected areas.

Fortescue Zero Battery and Power Systems

Battery-electric power systems are central to the company’s work. Fortescue Zero develops integrated solutions containing battery modules, power electronics, converters, control systems and software. These systems are built for demanding industrial equipment rather than ordinary passenger vehicles.

Its technology can support haul trucks, graders, dozers and other off-highway machinery. Mining vehicles often work continuously in severe conditions, so batteries must tolerate heat, vibration and heavy loads while maintaining dependable performance. Engineers must also balance battery size, charging time, vehicle weight and operating range.

Fortescue Zero therefore treats electrification as a complete engineering challenge. The company studies how the battery, vehicle, charger and operating environment work together rather than developing each part separately.

High-Power Charging Technology

High-power charging is another major area of development. Fortescue Zero has created a 6MW charging system designed for extremely large industrial batteries. The system is intended to support heavy electric mining equipment that must receive substantial amounts of energy without remaining out of service for long periods.

The company has also developed a 3MW charging solution for machines including graders and dozers. These charging technologies are important because the commercial success of electric heavy equipment depends strongly on operating availability. A mining vehicle that takes too long to recharge can reduce productivity, even if the vehicle itself performs well.

By combining large batteries with fast charging, energy-management software and operational planning, Fortescue Zero aims to make electric machinery practical for continuous industrial use.

Elysia Battery Intelligence

Elysia Battery Intelligence is one of the company’s most important software technologies. It combines battery science, data analysis and advanced algorithms to improve the way batteries are monitored, controlled and maintained. The platform is designed to help operators understand battery health, ageing, performance and charging behaviour across vehicles and energy-storage systems.

The technology can be used in electric vehicles, heavy industrial equipment and Battery Energy Storage Systems. Better battery intelligence can help companies detect developing problems earlier, improve maintenance planning and make better use of expensive battery assets throughout their operating life.

Elysia Cloud and Embedded Technology

Elysia Cloud analyses battery data remotely across individual systems or large fleets. This allows organisations to compare battery performance, identify unusual behaviour and understand how operating conditions affect battery health. The ability to analyse batteries continuously can reduce unexpected failures and support more accurate maintenance decisions.

Elysia Embedded works inside battery-management systems and uses advanced algorithms to improve control and performance. Rather than relying only on basic measurements, the technology can provide a deeper understanding of battery condition and behaviour. Fortescue Zero states that Elysia can significantly improve battery life in suitable applications, helping operators increase efficiency while reducing replacement costs.

Jaguar Land Rover Partnership

Jaguar Land Rover selected Elysia technology for future electric vehicles under a multi-year agreement. The technology is intended to support battery longevity, safety, charging and vehicle performance. This partnership demonstrates that Fortescue Zero’s expertise extends beyond mining and industrial machinery into premium automotive applications.

The agreement also shows the commercial value of battery intelligence as electric vehicles become more advanced. Vehicle manufacturers increasingly need software that can accurately understand battery condition throughout the life of a vehicle.

Fortescue Zero Autonomous Fleet Solutions

Autonomous fleet technology is another important part of the business. In mining, vehicle automation involves much more than allowing a truck to drive without a person inside the cab. An effective system must coordinate routes, loading, charging, traffic movement, energy demand and production targets across an entire site.

Fortescue Zero develops technology intended to connect these different activities. By combining automation with battery and energy intelligence, mining companies can operate electric fleets more efficiently while improving safety and productivity.

Fortescue already operates large numbers of autonomous haul trucks in Western Australia. These active mining environments give engineers the opportunity to study how automated and electric equipment performs under genuine operating conditions rather than relying only on controlled testing.

Mining Partnerships and Electric Machinery

Mining remains one of the most important markets for Fortescue Zero. Fortescue has worked with major equipment manufacturers including Liebherr and XCMG as it develops a large zero-emission mining fleet. Its programmes cover battery-electric haul trucks, electric excavators, zero-emission dozers and other machinery required for major mining operations.

Fortescue Zero contributes battery systems, power technology, engineering integration and software expertise to these programmes. Fortescue has also worked with MacLean on electric graders using its battery technology. Working with established manufacturers allows Fortescue Zero to concentrate on advanced technology while its partners provide the industrial-scale manufacturing needed for large fleets.

Fortescue Zero Motorsport and Formula E Technology

Motorsport remains an important part of the company’s identity and development strategy. Fortescue Zero provides PIT BOOST charging technology for the ABB FIA Formula E World Championship. The system can deliver 600kW charging power, allowing race cars to receive additional energy during a very short pit stop.

Formula E provides an extreme environment for testing charging systems, battery performance and thermal management. Technology used successfully in racing can later influence solutions designed for road vehicles and industrial applications. This relationship between motorsport and industry continues the engineering approach that began during the Williams Advanced Engineering era.

The Infinity Train Project

The Infinity Train is another significant project associated with Fortescue Zero. The concept involves battery-electric freight trains used to transport iron ore. Loaded trains travelling downhill can recover energy through regenerative braking, allowing electricity that would otherwise be lost to be stored in the train’s batteries.

That stored energy can then help power the empty train on its return journey towards the mine. The concept has the potential to reduce diesel use and limit the amount of external charging required for railway operations. Development work on the project began soon after Fortescue acquired Williams Advanced Engineering.

Fortescue Zero Across Other Industries

The company’s capabilities extend well beyond mining. It provides technology and engineering support for automotive, construction, infrastructure, stationary energy storage and motorsport applications. Construction businesses can use a combination of electric hardware, software and technical services, while infrastructure projects can benefit from charging systems, power conversion and stationary battery technology.

For stationary energy storage, Elysia can monitor battery health and help operators understand how much usable energy their systems can deliver over time. This can improve operating decisions and support better returns on investment.

Fortescue Zero Decarbonisation Advisory

Fortescue Zero also provides engineering and decarbonisation consultancy for organisations that need a practical path away from fossil fuels. Its teams can examine vehicle routes, energy requirements, fleet size, operating duties and charging needs before major equipment purchases are made.

Simulation and modelling can then be used to compare different options. This approach helps organisations understand how new technology could affect productivity, costs and energy consumption before large investments are committed.

The company therefore operates as more than a manufacturer or technology developer. It also acts as a systems integrator and technical partner capable of helping businesses plan complete industrial decarbonisation programmes.

Fortescue Zero Business Strategy in 2026

Fortescue Zero entered a new stage of development during 2025 and 2026. Instead of trying to manufacture every major technology itself in Britain, Fortescue increasingly began working with global manufacturing partners capable of producing equipment at greater scale.

The UK operation now places stronger emphasis on research, high-performance engineering, software, battery intelligence, intellectual property and systems integration. This strategy allows specialist teams to concentrate on developing technology while experienced manufacturing partners handle high-volume production.

Fortescue Zero Leadership and Ownership

Fortescue Zero operates within Fortescue Ltd, the global resources and energy group founded by Andrew Forrest. The UK business continues to operate legally as Fortescue Zero Limited and remains part of the wider Fortescue organisation.

The company has experienced leadership changes during its recent strategic transition. Ellie Coates previously led Fortescue Zero before stepping away from the chief executive position in 2025. Responsibility for the business then became more closely connected with senior Fortescue leadership as the organisation adjusted its technology and manufacturing strategy.

The Future of Fortescue Zero

Fortescue Zero combines motorsport engineering, battery science, advanced software and heavy industrial experience in an effort to solve some of the hardest challenges in decarbonisation. Its technologies are being developed for environments where equipment must remain productive while handling extreme loads and operating conditions.

Its future direction is increasingly centred on advanced engineering rather than large-scale British manufacturing. Battery intelligence, charging systems, autonomous fleet technology, high-performance power systems and engineering partnerships are becoming central to its strategy.

From Formula E charging and Elysia Battery Intelligence to electric mining trucks, autonomous fleets and the Infinity Train concept, Fortescue Zero is working across several parts of the transition away from fossil fuels. Its combination of racing heritage, industrial testing and global partnerships gives the business an important role in the development of practical zero-emission technology for heavy industry.

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