How the mining industry is developing in the era of automation and digitization

Automation, digitization and artificial intelligence are driving a metamorphosis of the mining industry toward more efficiency and safety.

In this new era of data, it is key to reconfigure corporate and operational practices to allow the desired increase in production without losing sight of new social, environmental, economic and even political standards, according to Liv Carroll, global mining and natural resources leader at Accenture.

In this interview, Carroll tells BNamericas about the main technological trends to optimize mining.

This is the first of a two-part interview. The second part will be published in the coming days and address governance challenges to face the effects of climate change on mining.

BNamericas: How is the mining industry advancing toward automation?

Carroll: Autonomous operations are increasingly being implemented to increase safety and efficiency and, in some geographies, tackle labor shortages.

At first, they focused on mobile equipment such as trucks, trains and drilling rigs, and in recent years, they focused more on the automation of processes, such as train loading, and actions related to data from machine learning and AI.

In addition, remote and integrated operating centers [ROC/IOC] continue to be developed that allow remote control and monitoring of equipment and operations, such as autonomous transport systems, rock crushers, LHD [load haul dump machines], drilling, drones and others.

BNamericas: What advantages do ROCs offer?

Carroll: By enabling remote monitoring, control and automation of mining operations, the need for personnel to be physically in hazardous environments is reduced, and the risk of accidents is minimized.

Additionally, they facilitate a rapid response to operational performance issues, such as unplanned shutdowns, and make operational performance visible with near real-time data and advanced analytics that enable informed and timely decisions.

The use of predictive analytics in ROCs enables proactive equipment maintenance, reduces unexpected failures and improves operational efficiency. Likewise, it allows remote control of automated machinery and equipment, such as autonomous trucks and drilling systems, increasing operational efficiency and reducing human errors.

ROCs also enable data-driven operations and advanced analytics with predictive AI so operators can respond to unforeseen emergency situations, enabling rapid evacuation and intervention. They favor a more receptive and preventive industry, maximizing safety, efficiency, sustainability and profitability.

BNamericas: What other benefits do remote operations provide?

Carroll: Not only does safety improve by having fewer people working with heavy equipment, but remote and integrated operations are more efficient and reduce equipment wear and tear, translating into a reduction in operating costs, as it allows problems to be resolved quickly and measures to be taken before they occur.

ROCs also help attract more labor by offering a safe workplace, in many cases closer to home.

To introduce more autonomy, it is necessary to allow access to data through AI and machine learning so that human operators make data-driven decisions and execute them quickly. Therefore, many mining companies are investing in digital twins in essential parts of the operation, such as the ball mill, processing plant or the smelter, since they allow multiple scenarios to be modeled, optimized and automated from the mine to the port.

BNamericas: Where is the Latin American mining industry in terms of automation?

Carroll: Latin American mining is positioning itself as an important player on the global scene. Chile, Peru and Brazil have important mineral deposits, particularly copper, lithium and iron ore, and are at the forefront of the adoption of autonomous technologies in the region.

Investment in AI and automation is expected to increase the competitiveness of Latin American mining.

BNamericas: How much are mining companies investing in innovation and AI?

Carroll: They are investing significantly in innovation and digital intelligence to improve safety, efficiency, sustainability and profitability. There is a transformation from exploration to customer experience, both in corporate functions and operations. This is largely driven by the transition to low-carbon economies and by changes in the expectations of society, labor and investors, where business models based on circularity are sought to satisfy the demand for minerals.

According to Accenture figures, 95% of executives managing natural resources and mining operations see technology as a key element for competitiveness. Between now and 2030, investments in digital technologies and AI are expected to drive substantial changes in operational efficiency and sustainability.

The World Economic Forum and Accenture highlight partnerships to create systemic efficiency, electrification and carbon capture in industrial clusters, with the potential to save more than 300Mt of CO2 by 2030, protect 17.8mn jobs and contribute US$2.5tn to global GDP by 2050.

BNamericas: What are the trends in digitization and mining technologies?

Carroll: Autonomous and remote operation, cloud data hosting, advanced analytics, AI, database, digital core and digital workforce. Automation is sought in trucks, drilling equipment, in trains, and in processes with generative AI that provides greater access to organized and quality data to guarantee reliability of knowledge.

Data silos and traditional processes lead to data quality issues, data duplication, and lack of a single source of truth. Therefore, advanced analytics and AI are being applied throughout the mining value chain, from the first phases of exploration with prospective analysis, through capital projects and follow-up on project delivery.

Algorithms allow analyzing data trends in operational equipment and predict failures to avoid downtime, reduce equipment unavailability and reduce the carbon footprint. The application of digital technologies in mining reduces costs, process time, waste, emissions and water consumption. At the same time, it provides greater recovery and production.

BNamericas: What innovations exist to achieve reuse of surplus minerals regarding tailings management?

Carroll: The 2020 Global Industry Standard on Tailings Management report catalyzes significant advancements in tailings storage facilities through smarter monitoring with IoT and AI.

At Accenture we promote smart tailings management, combining sensors, meteorological satellite data and studies carried out by drones that – through a control panel and machine learning algorithms – predict trends in deformation or water levels, generating automated alerts.

Several companies are trying to reprocess excess minerals from tailings with new processing technologies, to reuse them in other products, such as aggregates, through the circular economy.

To exclude waste, alternative processing is being used, such as bioleaching. Anglo American, for example, has pioneered dehydrated waste, known as dry cell waste.

In general, the technological transformation of recent years has improved effectiveness in the supervision and management of waste facilities, significantly reducing risks.

BNamericas: How can the decarbonization of transportation and mobile mining equipment advance?

Carroll: Large mining companies are adopting electric fleets of trucks or light vehicles, like Codelco's El Teniente division, which has a fleet of electric buses to transport workers. Decarbonizing mining transportation, particularly Caex trucks and other mobile equipment, is a critical challenge.

The mining industry is exploring solutions to replace fossil fuels with clean energy, among them, electric vehicles, hydrogen-powered trucks and hybrid trucks. The use of autonomous vehicles results in lower fuel consumption and fewer emissions. More and more EVs are also being used underground.

The Electric Mine working group of the Global Mining Guidelines Group [GMG], of which Accenture is a member and I am a director, published the third version of the recommended practices for EVs in underground mining in 2022, which includes content on security, risk, emergency response, maintenance and automated connection interfaces.

Through GMG, mining companies and suppliers are collaborating to solve this major challenge, which is the most significant transformation in the history of mining.

BNamericas: And how does the concept of a mining industry 4.0 advance?

Carroll: At Accenture, we believe the world is in the era of Industry X that considers the use of technologies for business intelligence and connects design, engineering, procurement, construction and capital management to ensure projects are delivered on time and on budget.

We are working with clients to develop digital twins combined with AI to redefine processes and increase efficiency. Using data and digital technologies such as AR/VR, cloud, AI, 5G, robotics and digital twins, miners are building more resilient and agile businesses for the future.