Embracing Mining 4.0: Technological evolution and challenges

Growing mineral demand, new regulatory requirements and geopolitical volatility have placed greater pressure on mining companies in recent years. In 2023, ABI Research surveyed industry representatives to understand how they expect technology to reshape their businesses. It found that the key drivers for change are centered on supporting sustainability goals; becoming more resilient to external supply shocks, political risks and local economy changes; and optimizing workforce safety and operations. The survey — which had some 500 respondents from the United States, Japan, France, Germany and the United Kingdom across a range of industry sectors, including 50 from mining companies — was conducted to gain a deeper understanding of the competitive environment. The aim was to discover how far industries had come in their digital transformation (Industry 4.0) journey and what they hoped to achieve through it. In the mining sector, Mining 4.0 allows companies to take advantage of technological innovations to revolutionize the entire value chain, from pit to port. Through Mining 4.0, they can harness the potentials of automation, artificial intelligence (AI), the internet of things (IoT), machine learning, data analytics and more to achieve their goals. Like any adoption of new technology, there are challenges. Adopting Mining 4.0 will require a shift in their approach from site exploration to customer delivery, and this article aims to discuss how they can do this to gain the greatest competitive advantage. Implementing a safer workplace Even with the increased regulations introduced in recent years, mining has inherent dangers. Mineworkers work alongside massive industrial machinery such as dump trucks weighing hundreds of tons, rock drills, hydraulic shovels and more. They often work at tall heights or in tight spaces underground and are exposed to explosions, fires, dust, gas leaks, cave-ins, floods and extreme temperatures in some of the world’s most remote and rugged locations. One of the most compelling use cases for increased Mining 4.0 worker safety is the introduction of teleremote and autonomous operations. This allows companies to separate the human workforce from hazardous situations, reducing the potential for accidents, including those created by human error, and increasing productivity and efficiency by improving their asset utilization. In addition to automating traditional operations, more companies are now using other automation technologies like drones. The ability to swap out payloads and fly beyond visual line of sight (BVLOS) allows them to deploy drones more quickly and safely in hazardous environments above and below ground. Equipped with high-definition cameras and thermal, ultrasonic or air-quality sensors, they can record the impact of blasting activities on underground tunnels to determine if columns should be fortified. They can be flown to inspect haulage road conditions, measure air quality or manage regular perimeter patrols. Within the context of continuously optimizing situational awareness and intelligence, Mining 4.0 also allows companies to automate data collection from myriad IoT sensors. Automated data collection means mineworkers do not have to traverse hazardous terrain in extreme temperatures to take regular readings. In mines, where temperatures can drop to minus 26 °C (minus 15 °F) and teams can be working in perennial darkness, snow and winds, workers have already seen the benefits of remote environmental data collection and monitoring. Predictive maintenance is also made possible by connecting and monitoring vehicle and other equipment data, allowing teams to be alerted to potential issues and manage timely maintenance activities to prevent incidents from occurring. One of the simplest ways to protect mineworkers is to equip them with ruggedized devices such as handhelds and tablets that can operate in extreme temperatures and allow them to rapidly share voice, video and data. Taking the connected miner a step further, in areas of extreme noise, helmets with integrated noise-canceling and hands-free headsets ensure communication is not impeded by personal protective equipment (PPE). Wearable devices allow companies to keep track of worker biometric information or pinpoint where they are in hazardous locations, and combined with environmental sensory data, can alert teams to potential issues, ensuring workers are evacuated from an area before an incident occurs. Sustainable and productive operations While just some of the benefits of Mining 4.0 for worker safety have been highlighted by implementing those capabilities, companies can also accomplish sustainability and productivity goals. For example, the ability to automate data collection from sensors at tailings dams, underground waterways and at blast sites will allow them to act on that data promptly to avert disasters and reduce the impact of mining activities. Drones too can be used to enhance mining sustainability and productivity. Some companies are using them equipped with loudspeakers to protect the ecosystem and scare wildlife away from blasting sites. Others are gaining more accurate stockpile readings to better inform the market on mineral availability. Drones also can contribute to more efficient and sustainable mine exploration, when used with payloads such as magnetometers and geographic information systems (GIS) to better identify mineral-rich locations. Leveraging autonomous operations, including haulage trucks, companies benefit from more efficient fuel consumption and operational precision. Predictive maintenance reduces part breakages and extends equipment life. Maintenance activities and workforce training can also be augmented, as connected workers are able to scan machinery using their devices and be guided, using AI and mixed reality, to areas that need attention, watch videos to guide them through processes or connect with offsite experts. Miners are also investing in the concept of “electrification of the mine,” introducing electric heavy machinery. This will present a new set of opportunities and challenges, as operational cost savings are created and new infrastructure and operating constraints will need to be managed by the network as well. Building the foundation for Mining 4.0 with private wireless All these capabilities and more can only be supported through the right mix of technology. The Mining 4.0 journey must begin with the implementation of a robust, pervasive and flexible wireless connectivity layer. Private wireless networks that use 4.9G/LTE and 5G technology have been digitally transforming mines for more than a decade — with the first private LTE network deployed at Rio Tinto’s iron ore mine in Western Australia in 2012 — and there are many reasons why. Private 4.9G/LTE and 5G wireless networks are built with security in mind, using the same technology designed to protect cellular networks around the world. 4.9G/LTE and 5G radios offer a greater coverage range than technologies such as Wi-Fi, and can connect more devices, sensors and people. Even as connectivity grows, they are reliable, providing the low latency connectivity required and allowing companies to prioritize mission-critical services such as autonomous vehicles and maintain the constant-heartbeat network connectivity that is vital to keeping workers safe and operations productive. To support mission-critical Mining 4.0 applications such as autonomous equipment and vehicles, alongside this robust, resilient connectivity layer, companies must also implement an industrial edge. This allows data to be processed in real time close to the source. The ability to implement micro edge services and have data processed closer to where they are being generated will allow companies to scale worker safety systems as their needs evolve. To connect workers and equipment, companies must implement devices that are designed to withstand the harsh remote environments of mines, and they must be able to deploy Mining 4.0 applications that help them achieve their unique goals. Overcoming challenges With the right technological mix in place, companies will achieve the greatest benefits, but there are challenges. Connecting industrial equipment, selecting suppliers, testing and integration, retraining the workforce and shifting expectations can be overwhelming, but these challenges can be overcome.Let us first look at connecting equipment and vehicles. No company is going to want to replace existing equipment if they do not have to. Leveraging ruggedized 4G/LTE and 5G routers and dongles, they can maximize the return on existing investments and reliably connect haulage trucks, drills and more to the private wireless network infrastructure.But with an array of devices and applications available — how can they select the right ones for them? This requires a collaborative approach across the company, ensuring business goals are accurately visualized before investments are made. Results from the survey show that a lack of alignment between information technology (IT) and operational technology (OT) needs could impede the progress of digitalization. Mining companies that adopt a private wireless-as-a-service platform will have the greatest advantage, allowing them to grow their investment and capabilities in alignment with their needs. Once a mining company has defined its goals, it can be overwhelmed by the number of vendors from which to select. How can it integrate connectivity, edge processing and devices and applications to ensure they work seamlessly? Choosing a vendor that has done this work for them can help in this aspect.By leveraging a preintegrated and tested platform that incorporates robust, reliable private wireless connectivity, industrial edge processing and an ecosystem of devices and applications, companies can more rapidly achieve their goals. It is clear why mining companies around the world are turning to private wireless to enable their digital transformation. Whatever approach they take, choosing a single, integrated industrial private wireless platform is an option for companies to achieve their business goals faster and gain the greatest competitive advantage. n Reference Nokia (2023) “Nokia and ABI Research unveil Industry 4.0 maturity index for industrial campuses” https://www.nokia.com/about-us/news/releases/2023/04/17/nokia-and-abi-research-unveil-industry-40-maturity-index-for-industrial-campuses/

Embracing Mining 4.0: Technological evolution and challenges

Authored by: Jamie Laguna

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