The mining industry has always been at the forefront of technological evolution, from steam-powered engines to autonomous systems. Mark Venables discusses how these transformations reshape mining operations to meet future demands.
Mining is critical in the energy transition, providing essential minerals like lithium, cobalt, nickel, and copper, which are crucial for renewable energy technologies, electric vehicles, and battery storage. Without these raw materials, the ambitious goals of transitioning to a low-carbon economy, such as widespread adoption of wind, solar, and electric mobility, cannot be realised. Mining, therefore, forms the backbone of the energy transition by ensuring a steady supply of the materials needed for clean technologies.
However, traditional mining practices often face scrutiny for their environmental impact, including significant carbon emissions, water usage, and disruption to local ecosystems. To align with the principles of the energy transition, the mining sector must improve its sustainability credentials. This is where artificial intelligence (AI) can play a transformative role. By leveraging AI, mining companies can optimise their operations, enhancing energy efficiency, reducing waste, and minimising the environmental footprint. AI-driven predictive maintenance, real-time monitoring, and automated decision-making can also help reduce greenhouse gas emissions and improve resource management.
Ultimately, embracing AI technologies is vital for mining to responsibly meet the demand for critical minerals, contributing to the energy transition while mitigating its environmental and social impacts.
From Industry 4.0 to Industry 5.0
In an Industry Viewpoint session at Rockwell Automation Fair the future of mining came under the spotlight. The mining sector has been moving through distinct phases of industrial revolutions, with each stage built upon the previous. “Initially, Industry 1.0 saw the introduction of steam-operated equipment, effectively replacing manual labour and dramatically increasing productivity,” Farah Kaboodanian, Control Automation Global Discipline Director, Hatch explains. “This transition was followed by Industry 2.0, with electricity and oil providing more power and pushing the industry into a transformative period of enhanced machinery and complex operations.
“The real change came with Industry 3.0. Programmable logic controllers (PLCs) and computers brought automation to mining. It enabled the standardisation and control of complex processes, improving safety, precision, and reliability. Today, the sector is firmly in Industry 4.0, characterised by network-driven digitalisation and autonomous operations. We see unmanned trucks and drones, real-time monitoring, and predictive maintenance. These technologies optimise operations and pave the way for a safer and more efficient future.”
Kaboodanian foresees a shift towards Industry 5.0, where automated equipment, human workers, and AI-based digital systems will work in tandem. “We envision three types of miners in the future: the robotic miner, the human miner, and the digital miner. These entities will collaborate to create a more resilient, optimised, and safer mining ecosystem.
“While Industry 4.0 has achieved significant automation, there are still gaps in human-machine interaction, particularly in complex decision-making scenarios. AI and machines still need to gain trust in managing all safety and efficiency aspects. This is where Industry 5.0 will play, ensuring a seamless interaction between humans and machines.”
Navigating the complexities of automation
Delivering automation projects in mining is not without its hurdles. Kaboodanian highlights the challenges posed by increased process design complexity. “Process designs today are highly intricate, requiring several modifications to optimise production and achieve desired grades,” she adds. “These changes are often communicated late to automation teams, leading to misalignment, rework, and delays in project schedules.
“The fragmented nature of traditional project delivery models compounds these challenges. Multiple stakeholders, EPC contractors, system integrators, and automation vendors are typically involved, which often leads to a lack of coordination and consistency. This can result in significant delays, particularly when automation contractors are brought in after substantial engineering decisions have already been made. Integrating equipment from various vendors further complicates matters, especially when information on vendor-supplied equipment arrives late in the project cycle.”
To overcome these challenges, Hatch has explored several alternative approaches to project delivery. Our preferred approach is the integrated automation team. This team includes representatives from the owner, EPCs, and automation contractors, working collaboratively from the beginning of the project. By having an integrated approach, we ensure that automation considerations are factored into every decision, reducing the risk of late changes, miscommunication, and misalignment.
Leveraging technology to reduce operational costs
Cost reduction is a critical objective in the mining sector, and technology plays a pivotal role in achieving it. Kaboodanian underscores several ways technology can contribute to cost savings. “Standardisation is one of the most effective measures,” she begins. “Maintenance becomes significantly easier and more cost-effective by ensuring that equipment, control panels, and designs are standardised across the entire facility. Standardising elements like cable numbering can help maintenance teams quickly identify issues, reducing downtime and associated costs.
“Data integration is another key area of focus. Effective data integration unlocks the full potential of automation. We live in an age where data is valuable, but it is often not given enough attention during the design phase. By focusing on data integration from the outset, we can provide operations teams with the insights they need to make informed decisions, improve efficiency, and reduce costs.”
Non-DCS operational systems, such as fleet and maintenance management systems, also play a crucial role in mining operations. These systems need to be designed and integrated correctly to ensure seamless operation with the overall control system; this highlights the importance of a holistic approach to technology integration.
Reducing variability and maximising performance
Advanced Process Control (APC) has become a powerful tool for reducing operational costs and improving mining productivity. Kaboodanian describes the multi-tiered approach Hatch takes with APC. “The first step involves tuning the existing PID loops, which can already significantly impact reducing variability,” she continues. “Once the basic control loops are optimised, we move to supervisory or higher-level control strategies, looking at the overall process and how different variables interact.”
The pinnacle of APC, she explains, is Model Predictive Control (MPC). “MPC takes into account multiple inputs and outputs, using a dynamic model of the process to predict future outcomes and adjust control actions accordingly,” she explains. “By reducing process variability, MPC helps bring the system closer to optimal performance. It effectively reduces energy consumption, improves productivity, and maximises equipment efficiency.”
Kaboodanian stresses the dual impact of APC: Firstly, it reduces variability, leading to more stable operations. Secondly, it ensures that equipment operates as closely as possible to its design specifications, maximising efficiency and productivity. This is particularly important in complex mining operations, where slight variations can significantly impact overall production and costs.
The future of mining: AI, cybersecurity, and zero-entry mining
AI is increasingly embedded in mining operations, with applications ranging from vision systems to predictive maintenance. “One of the most established applications is using AI for vision and object detection,” Kaboodanian says. “For example, in one project, AI cameras were used to monitor shaft activity, providing real-time insights and automating the traditionally manual and error-prone process of tracking material and personnel movement.”
AI is also being leveraged to enhance safety. “AI-driven systems can monitor compliance with PPE requirements, detect unauthorised access to restricted areas, and prevent collisions between mobile equipment and personnel,” she says. “These safety systems add an extra layer of protection, helping operators avoid mistakes and ensuring safety protocols are followed.”
In this new connected world, cybersecurity, Kaboodanian emphasises, is crucial for the future of mining, particularly as operations become increasingly digital. “The convergence of physical and digital assets exposes mining operations to a range of cyber threats,” she emphasises. “Cybersecurity measures are needed to protect against these threats and ensure the integrity of both digital and physical systems.” She highlighted the importance of regulatory compliance, noting that mining companies must align with evolving digital security standards to avoid penalties and maintain stakeholder trust.
On the topic of zero-entry mining, Kaboodanian offered an intriguing glimpse into the future. “Zero-entry mining is a concept where operations are fully automated, and no human presence is required on-site,” she explains. “This is already being implemented in some regions, such as certain mines in Norway, where operations are automated to the point that if a human enters the mine, the entire operation automatically shuts down for safety.”
While the concept is promising, Kaboodanian acknowledged the challenges involved. “The industry is not yet at a point where human workers and automated equipment can operate seamlessly in all environments,” she concludes. “The challenge lies in developing AI and control systems capable of handling complex decision-making in dynamic environments. However, as technology advances, we expect more collaboration between human workers and machines, paving the way for a safer and more efficient mining future.”
