The Future of Mining Automation: Overcoming Challenges Through End-To-End

(E2E) Mining Automation Platform

The mining industry is at a critical juncture, facing both increasing demand and formidable
challenges in its operational landscape. Traditionally labor-intensive, the industry is now
witnessing a transformative shift towards extensive automation. In this article, we delve into
the multifaceted challenges currently confronting mining operations, spanning safety
concerns, declining ore grades, rising energy costs, and fragmented information systems.

Challenges in Mining Today

. Remote Workforce Recruitment and Safety: Mining companies, now multinational

giants, often operate in geographically distant and harsh environments. The
recruitment and retention of skilled personnel for remote operations, particularly in
deserts, pose a significant challenge. Safety concerns persist, with accidents triggering
stricter regulations.
. Declining Ore Grades and Deep Mining: Mines are delving deeper to extract ore,
resulting in declining ore grades. As costs rise, maintaining productivity becomes a
pressing issue, necessitating innovative approaches to extraction.
. Energy Costs and Efficiency: Rising energy costs have long been a concern for the
mining industry. Efficiency and energy consumption tracking are pivotal for
sustainable operations, demanding a seamless integration between processes and
energy management.
. Information Fragmentation: The industry grapples with a multitude of independent
equipment and systems, each with its own interfaces and data. Lack of unity in
automation, from controllers to operators, impedes timely decision-making and
creates information gaps in the value chain.

Solutions directive: Improve productivity

The response to these challenges could be solved via production improvement can alone
support and address most of the concerns above. However, the most pressing challenge in the
mining industry as of today is siloed operation. Examining a comprehensive mining operation
inclusive of processing reveals a significant business challenge. This operation consists of
four distinct process areas, each managed by operators overseeing their respective machines.
The absence of collaboration and integration among these areas creates a formidable obstacle
in optimizing the entire value chain. The crux of the matter lies in establishing a unified view
of production, spanning from raw material extraction to processing, stockpiling, and final
delivery. An integrated solution is imperative to address the existing gaps within the value
chain. To illustrate, effective communication can enhance coordination between activities
such as blasting and crushing in the mine and the grinding process in the concentrator. In
essence, the primary business challenges encompass ensuring safety, addressing declining ore
grades, managing escalating energy costs in remote locations, and bridging information gaps
within the value chain.

Addressing Challenges: E2E Mining Automation Solution

In response to these challenges, the key solution is an an evolution in mining operations
through Extended Automation. This paradigm envisions the convergence of equipment,
systems, and personnel into an integrated and unified ecosystem. Consider a mining site that
comprises of four distinct areas managed by local, specialized operators. While the current
setup is cost-intensive, our objective is to enhance efficiency by bringing these areas together,
fostering uniform communication, and integrating them into a unified system where all
pertinent information is readily available. Although local controllers are in place, the
prevailing trend leans towards centralized operations. Modern control room designs facilitate
collaboration among individuals with diverse roles, breaking down barriers and consolidating
control rooms. This approach enables experts to collaborate seamlessly in one location. The
implementation of extended automation serves to bridge gaps in the value chain, establishing
a safe, reliable, and predictable production process. The enhanced visibility spans from the
mine to the concentrator, smelter, and stockyard, resulting in an optimized operation
extending seamlessly from the mine to the port.

Here are some practical examples of E2E mining automation solution in work:

1. Asset Management: Let's start with asset management, a very important matter.
Piece of machinery and the operator has just been alerted by a predictive maintenance
module. As it will be needing repair, the operator can access the maintenance system
and see all upcoming work orders. Easy to add new work orders. He comes to the
field engineer who used the same information on his mobile device. Together they
decide on optimal maintenance action.
2. Ventilation Management: Here is an example of how to control rising energy costs.
Some months ventilation accounts for almost 50% of energy consumption. vehicles
 emit diesel exhaust that have to be painted away. The automation system knows
where each vehicle is at. All vehicle data, including emission levels, is communicated
to the system. The installation is continuously optimised for actual need at the airflow
can be adjusted at anytime. Energy consumption, while preserving and quality, means
great savings with the integration of process and power alternation. In System, energy
usage can be measured in real time. It enables operators to detect energy fees in any
area of the plant.
3. Processing Plant Performance: What about increasing the processing plant
performance in a consistent and reliable manner? In the processing plant, impurities
are eliminated from the order. Before smelting, the glass needs to react quickly to all
property changes. With extended mining automation system this becomes possible.
Tracks material movements and properties all the way from the mind to the
processing plant. Properties are locked and represented graphically, eliminating gas
work. The information is available for other advanced applications as well as to
support operators actions. Material movements are automatically synchronised with
inventory management systems that look after the logistics and the supply chain.
Finally, all information is used by process optimization controllers the use forecast of
the old properties to make predictive adjustments to the grinding and flotation secret.
The result is higher equipment utilization, increased production and lower and if you
consumption. Mining companies are become multinational giants with mines
scattered all around the world.

In conclusion, extended automation emerges as the solution to the challenges facing the
mining industry. Through the unification of equipment, systems, and personnel, mining
companies can enhance productivity, safety, and sustainability, ultimately optimizing their
operations from mine to port. The E2E mining automation system plays a pivotal role in
realizing this vision, providing a modern and integrated platform for the future of mining
automation.