You can’t flip through a mining magazine these days without reading about the Internet of Things (IoT). There’s a good reason for that. IoT has endless promise to deliver cost savings at a time when operators are hungry for any efficiency they can get.
But much of what’s been written about IoT in the mining industry leads to a vague or cursory understanding of the subject. How can IoT be applied to specific parts of a mining operation to make it leaner and stronger? Here are three examples.
1. Predictive maintenance
Australian mining companies spend a lot of money on maintenance. Reactive maintenance results in costly downtime as unforeseen breakdowns cause the production chain to slow down or stop. Preventative maintenance involves replacing parts before they reach the end of their life cycle. This might be cheaper than unscheduled downtime, but it still represents a lapse in efficiency.
Operators can shift this dynamic by fitting heavy equipment (e.g. haul trucks, excavators, conveyor belts) with smart sensors. By delivering data on key performance metrics (e.g. heat, vibration, rotation, engine speed, brake pressure, oil temperature, contamination, etc.), sensors like the ones made by MachineQ, Bestech, Steinert and others represent a new horizon of performance monitoring and targeted maintenance.
Thermal cameras are another IoT tool operators can use to improve maintenance protocols. By monitoring temperature irregularities in real time, thermal cameras offer a “hands-off” approach to internal equipment monitoring. Of course, the key to using IoT for targeted maintenance is not only harvesting good data, but also having a solid program to interpret that data and generate insights.
2. Ventilation
As viable orebodies recede, underground operations are a focal point for mining companies in Australia and around the world. There are several ways in which IoT can deliver value underground, but ventilation is one of the most interesting, as it lightens energy footprints whilst improving safety.
At Goldcorp’s Éléonore gold mine in Quebec, Ventilation On Demand (VoD) has been in development since the early 2000s. The idea is simple: All underground workers and equipment are fitted with tracking devices, which interact in turn with a network of automated fans. In short, targeted ventilation is triggered by the real time movement of people and equipment within the mine.
The system has evolved through time, and was awarded Ecotech Quebec’s Eureka Prize in 2019. According to a case study by Cisco, who helped design the systems, VoD results in energy cost savings up to A$4 million per annum. Howden, another company involved in the project, breaks down the savings as follows: a 43% drop heating costs, a 56% drop in ventilation electricity costs, and a 73% drop in surface ventilation electricity. Better monitoring of personnel and air quality are two additional benefits of VoD.
3. Robotics
The white whale of IoT for the mining industry is robotics. Its potential to transform the way mines are designed, from both a technical and human resources standpoint, is exciting – but it’s also fearsome. For example, there are real questions about how local economies will benefit from automated mining, and how outplaced workers will be upskilled or transitioned to new roles within the industry.
That said, automation is too valuable to be stopped. Hauling is the most reliable example we have today. Rio Tinto’s robust investments in automated trucks and trains for its operations in Pilbara have resulted in a 15% boost in productivity, according to the company. If these kinds of numbers are available for early adopters, imagine what will be possible as the technology evolves, and as the barrier to entry is lowered.
Apart from the all-important task of hauling, IoT robots can deliver real-time site mapping and analytics with the use of automated drone flights. Automated and remote-controlled drilling does not yet enjoy a strong proof-of-concept, but it seems fair to assume that automated drill rigs will evolve quickly, and there are promising developments. Syama Gold Mine in Mali has been billed as the world’s first fully automated mine, and seems fairly close to earning that designation.
A Down-to-Earth Approach to IoT
For mining operators, it can be a challenge to get past the vague excitement of IoT and stay focused on the reality at hand. There are an endless number of possible IoT applications, but as always, mining houses need more than possibilities. As always, a solid investment is characterised by a reputable partner who is committed to robust, demonstrable solutions.
