The global mining industry is undergoing a significant transformation, driven by a need for safer and more sustainable practices. The rise in remote operation and autonomy, mine site electrification, and alternative mining practices are at the heart of these changes.
As mining companies transition toward remote operation and autonomous mining activities, they are investing heavily in autonomous equipment such as shovels, haul trucks and loaders either operated with sensors and lidar (light detection and ranging), or remotely operated from a safe distance with onboard diagnostics and cameras. This shift not only removes workers from potentially hazardous environments and reduces the risk of bodily harm, but also can lead to increased efficiency and productivity in continuous operations under challenging conditions.
Underground mining allows for more selective extraction of higher-grade ore, minimizing waste rock removal. While underground mine planning and engineering traditionally presents safety and cost challenges because of the need for extensive collapse prevention practices to protect workers, the recent integration of autonomous and remotely operated equipment is making underground mining a safer and more viable option.
Electrification also continues to play a major role in the mining industry, replacing diesel-powered equipment with electric and battery-electric alternatives. This ultimately reduces greenhouse gas emissions and the mine site’s dependence on fossil fuels, contributing to a greener mining operation.
A prime example of technological development in the industry is Caterpillar’s Cat Dynamic Energy Transfer solution for battery and diesel-electric haul trucks. This system allows mining operators to move their fully laden trucks up the pit grade emission-free, reducing greenhouse gas emissions with an added production benefit of a faster haul cycle. Other electrification solutions include Komatsu’s WX04B battery-electric Load-Haul-Dump (LHD) machine and Epiroc’s Pit Viper 271 electric-driven blasthole drill rig. All of these technological solutions contribute to the industry’s growing embrace of electrification.
One aspect that’s important to consider in electrifying fleets is how much power is needed to charge and operate equipment. Large haul trucks can weigh around half a million pounds — with an additional payload in excess of half a million pounds. The auxiliary power needed to charge these huge machines can be upward of 4 megawatts per truck. How mine operators plan for, and balance, these large ancillary power loads — while maintaining a mine and processing operation — will be critical as the industry transitions to a decarbonized future.
Beyond autonomous, remotely operated and electrified operations, the industry is aiming at developing a safer, more sustainable and more productive mine of the future. This includes focusing on smaller surface footprint, underground mining techniques and the implementation of new, efficient processing technologies.
Resolution Copper's project in Arizona exemplifies the industry's commitment to these innovative practices. The proposed underground mine, expected to become the largest copper mine in North America and capable of producing 25% of U.S. copper demand each year, would use block caving, a highly efficient underground mining method. This method extracts copper while minimizing environmental impact. Additionally, Resolution Copper will use less than 5 gallons of water per pound of copper produced, compared to the 10-50 gallons per pound often found at other operations. The company will achieve this by leveraging technology to reduce evaporation and enable reuse and recycling of valuable water resources.
Enhanced mineral processing embraces the development of new technology — such as Rio Tinto’s Nuton venture or Freeport-McMoRan’s Leach to the Last Drop initiative — to increase recovery and reduce waste. These initiatives focus on safe production, along with improved maintenance and reliability. Miners are also leveraging zero liquid discharge technology from other industries to treat and reuse process water. Using these types of technological solutions helps to reduce overall water consumption and ultimately minimize environmental impact.
While the shift toward sustainable mining practices is gaining momentum, there are certainly challenges to overcome:
- The high initial investment cost of new technologies, such as battery-electric vehicles and autonomous systems, can be a barrier for some companies as they pursue environmental, social and governance (ESG) targets.
- Power dependency and how to balance energy will become bigger challenges as mine sites transition to electric and battery-electric equipment. This is further compounded as mine sites commit to a blend of traditional and renewable sources of energy, including utility grid connect, on-site generation, solar, wind and battery storage.
- Regulatory hurdles and permitting processes can slow down the adoption of new mining methods.
- Public perception and concerns about mining's environmental impact need to be addressed through transparent and responsible operations.
Significant industry changes and their associated challenges highlight the need for collaboration among mining companies, technology providers/original equipment manufacturers, and engineer-procure-construct (EPC) firms to successfully implement these innovative solutions. By working together, those in the mining industry can:
- Develop customized solutions tailored to the unique challenges and opportunities of each mining site.
- Integrate new technologies seamlessly into existing operations, maximizing efficiency and minimizing disruption.
- Drive innovation and push the boundaries of what's possible in sustainable mining practices.
The transition to a more sustainable mining industry is not just about adopting new technologies. It's about changing mindsets and fostering a culture of continuous improvement. By embracing innovation and collaborating with partners who share this vision, the industry can secure a brighter future for itself and the planet.
The global mining industry is embracing a transformative shift toward safer, more sustainable practices through advancements in automation, electrification and innovative extraction methods. By fostering collaboration among key players in mining and prioritizing continuous improvement, the industry is poised to navigate challenges and secure a more environmentally responsible future.
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