The Future of Mining Equipment
Electrification and automation drive technological innovation
Global Data reports that the metals and mining sector contributes 4% to 7% of worldwide greenhouse gas emissions. Over 50% of these emissions are generated by the transportation and loading of minerals. If the mining industry is to be a central player in the global energy transition, and if it is to demonstrate that mining can be done sustainably to the general public, there must be a transformative approach to reducing the industry’s carbon footprint.
Across Brazil, OEMs are innovating and bringing new machines to the market to meet the unique needs of the modern mining world. However, that innovation can and must speed up. Craig Milne, strategic advisor at Copperstone Technologies, believes that mining companies can support this by increasing their risk and investing in cutting-edge technology. “At the end of the day, the dollars are probably relatively small for mining companies to invest in innovative technologies, but they must be willing to take bite-sized financial chunks and move quickly to see what works and what does not. If the industry intends to become more innovative, it must be able to evaluate technology on a different scale then they do their standard supply chain.”
This is particularly true as the mining industry’s significant critical minerals exploration begins to develop into new projects, with a healthy number of greenfield projects in development. And, in the long-term, changing requirements will impact OEM makers. Brazil is 90 to 95% open-pit mining. However, some OEM producers mentioned the potential for companies to start underground operations, particularly in Minas Gerais. In the future, some currently open pit mines will transition to underground, providing an opportunity for OEMs to fulfill their needs.
Mining companies are thus embracing technological advancements in their quest for productivity and sustainability. Equipment manufacturers are keeping pace by developing equipment utilizing alternative energy sources, automation systems and digitalization technologies.
Automation offers multiple benefits, including increased safety. Copperstone Technologies, for example, has developed a robot capable of autonomously traversing tailings dams, which is essential for supporting the data collection activities necessary for safe tailings management. Traditional tailings research is carried out from human-crewed equipment, including specialty trucks and boats. Reducing the presence of humans in high-risk scenarios speeds up operations. Milne said: “When you put a human operator on tailings, there is always a high risk for the operator, and a lot of additional safety planning must go around the work.”
"Mining projects happen on cycles of several years, and large companies must be willing to take more risks. The mining industry’s timelines are too long and slow for efficient innovation."
Craig Milne, Strategic Advisor, Copperstone Technologies
Mercedes Benz is focusing on this aspect and recently launched the Arocs 8x4 on the Brazilian market. Among the most notable features of this truck is the increase in load capacity by almost 10 tons compared to the previous model. Another important feature of the Arocs 8x4 is the software adaptations that enable precise and efficient shifting. Marcos Andrade, marketing manager of Mercedes Benz in Brazil, explained: “We conducted rigorous testing with customers for two to three years before launching this platform, ensuring it emphasizes safety, efficiency and driver comfort while maximizing the load carrying capacity.”
Mercedes Benz has also launched another version of the Arocs 4x8 designed to be compatible with biodiesel. However, Andrade pointed out that biodiesel currently accounts for only about 1% of the total Brazilian truck market. Innovating for a future beyond diesel is an essential challenge the equipment industry is facing head on, but equally important is the focus of OEMs on improving equipment life and efficiency to operate in a more sustainable manner.
Advanced technologies are central for a greener mining industry, and electrification is at the core of that push. For Epiroc, electrification, digitalization and automation are key to increasing sustainability, productivity and safety. Kamshat Galiyeva, general manager at Epiroc Brasil, explained: "The Brazilian mining industry and our customers are investing in automation, digitalization and electrification technologies, such as Kinross, which has acquired two of Epiroc's fully autonomous drill rigs, the Pit Viper 275, for their Paracatu mine. We are in the process of converting their existing fleet in this mine into an autonomous fleet."
Epiroc's Smart and Green series combines the benefits of zero-emission technology and automation and digitalization tools. Since one of the main constraints to implementing these technologies at scale is the lack of proper energy infrastructure and connectivity, Epiroc also works with its customers to find solutions to these inconveniences. “Our approach is not only to supply the mining equipment but also to support the customer in terms of consultation for the mine infrastructure and design to ensure that electrification projects can be successful,” explained Kamshat Galiyeva.
Normet, an international OEM, is also highly cognizant of the significant infrastructural investment required by the transition to electric equipment. The company conducts studies to estimate the potential costs and requirements of key infrastructure such as charging station locations, and ensures that electric vehicles can operate according to the available supply and mine profile. According to Odilon Mendes, managing director of Normet Brasil, the benefits will rapidly surpass the costs of investment in this electrification infrastructure. Mendes stated: “At this moment it’s still challenging to imagine an all-electric fleet in underground mines but that will soon become a reality as the industry understands the benefit of this technology.”
Normet has been highly active in the Brazilian market in recent years, and is launching a new line of electric equipment called Normet SmartDrive. “The use of electric equipment has significant safety benefits for workers, as it reduces carbon dioxide emissions in mines, which is particularly important in underground operations that have limited ventilation,” said Odilon Mendes, managing director of Normet Brasil. “There is a remarkable shift towards electrification in the mining industry, and we are actively monitoring this trend.”
The electrification of mining equipment will, however, require a significant increase in electricity demand. For the carbon emissions gains of electrification to be impactful, that additional electricity must come from a renewable source. A McKinsey study determined that electrifying the mobile fleet of the global iron ore industry would necessitate 20 to 30 terawatt-hours of electricity more than currently utilized, equivalent to 10 to 15% of Australia’s annual electricity consumption. Brazil is unusually well poised to meet this demand due to its hydropower availability, but the industry at large must invest in diversified renewable energy sources to meet growing need for electricity as mining equipment transitions.
Image courtesy of Kinross