{"id":11480,"date":"2025-12-04T18:06:34","date_gmt":"2025-12-04T18:06:34","guid":{"rendered":"https:\/\/northamericanmining.com\/?p=11480"},"modified":"2025-12-04T18:06:36","modified_gmt":"2025-12-04T18:06:36","slug":"mining-4-0","status":"publish","type":"post","link":"https:\/\/northamericanmining.com\/index.php\/2025\/12\/04\/mining-4-0\/","title":{"rendered":"Mining 4.0"},"content":{"rendered":"\n

With innovative, digital technologies proliferating in mining, an intelligent future beckons.<\/em><\/strong><\/p>\n\n\n\n

by Jonathan Rowland<\/em><\/p>\n\n\n

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\"Mining
Mining companies can achieve their goals by becoming digital enterprises, utilizing end-to-end solutions, such as Siemens Xcelerator, to enhance efficiency throughout the mining process. Photo: Siemens<\/strong><\/figcaption><\/figure>\n<\/div>\n\n\n

The global pressures mining operations face will be familiar to readers of North American Mining<\/em>. The increasing demand for critical minerals, along with diminishing ore grades, tightening environmental expectations, the need for safer workplaces and skilled personnel, and fluctuating commodity markets, all place demands on this cost-sensitive industry. \u2018Intelligent mining\u2019 describes the industry\u2019s response, \u201cleveraging technologies to extract more value using fewer resources, while minimizing risk and environmental harm,\u201d as Stephen de Kock, managing director of EYEMINE, put it.<\/p>\n\n\n\n

This can go \u201cin any direction, whether focusing on asset performance, lifecycle, maintenance, operational performance, or operational and corporate management,\u201d said Sunny Schoone, global head of Automation and Digitalization at Innomotics Mining, a relatively new name in the mining industry, but one with an established pedigree, having been formed from Siemens\u2019 electric motors and large drive systems business in 2023. For Schoone, the essence of intelligent mining can be summarized as delivering actionable information from field data to enhance decision-making.<\/p>\n\n\n\n

The goal of the intelligent mining vision is to transform mining firms into \u201cdigitally operated mining companies,\u201d said Siemens\u2019 Thomas Walther. In such companies, digitalization encompasses every aspect of the value chain, from excavation to transportation, beneficiation, and storage. According to Walther, head of Vertical Minerals: \u201cEach digitalization step offers an opportunity to optimize individual processes; however, the most significant impact comes from combining all data to deliver an end-to-end digital twin that incorporates product, process, and plant design, engineering and commissioning, and ongoing mining production.\u201d<\/p>\n\n\n\n

This foundation enables the implementation of wide-ranging software solutions and end-to-end automation, with solutions that \u201cwould have seemed futuristic only a few years ago now becoming commonplace,\u201d Walther concluded.<\/p>\n\n\n\n

Critical to realizing the intelligent mine in the real world is shifting from siloed operating models to \u201cintegrated, whole-of-mine approaches,\u201d said de Kock, a perspective echoed by Schoone, who called cross-silo data usage \u201cone of the greatest potentials of digitalization.\u201d According to these experts, a mining operation that aggregates all data along the material value chain into a single point of truth can optimize in multiple directions simultaneously, including balancing optimum economic production with ESG impacts.<\/p>\n\n\n\n

Products, systems, and services within the intelligent mining ecosystem should be \u201cgeared toward helping mining companies optimize their entire value chain across the whole lifecycle,\u201d agreed Walther. This includes both horizontal \u201cpit-to-port\u201d integration and vertical integration between operational technology (OT) and information technology (IT) systems.<\/p>\n\n\n

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\"EYEMINE\u2019s
EYEMINE\u2019s EYE-ANALYSE reporting dashboard for weight and volumetric scanning data supports mines in their pursuit of a truly whole-of-mine approach to optimization with real-time, actionable data.
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Interoperability and data integration<\/strong>
Mining operations often end up a \u201cpatchwork\u201d of systems from different vendors, implemented at various times for different purposes, said EYEMINE\u2019s de Kock. This \u201cfragmented ecosystem\u201d presents several challenges to optimizing across the mining value chain, including data silos and quality issues, operational inefficiencies, inconsistent standards, and outdated systems that lack support for APIs or standard protocols.<\/p>\n\n\n\n

The \u201cart,\u201d explained Schoone, is to \u201cconnect all the various systems, both open and proprietary, and data sources, and harmonize into a single point of truth that makes them usable.\u201d<\/p>\n\n\n\n

Existing plants will \u201calready have hardware, software, and processes in place, some of which will have been around for decades,\u201d agreed Walther, who argued for the role of the end-to-end digital twin in breaking up data silos and ensuring that a mine\u2019s digital journey is carried out based on up-to-date (digitalized) documentation and relevant operating data.<\/p>\n\n\n\n

Life is a little easier in new mining projects. Early in process and plant development, a virtual production system is created to help design, simulate, and engineer process plants. \u201cUsing collaborative platforms as a basis and with complete data integration from design through to engineering and commissioning, it is possible to automatically create a digital twin for the plant, including automation,\u201d Walther explained. This can then be used in actual production with minimal outlay, thereby saving on engineering work and reducing the time it takes to get production up and running. \u201cThe same applies to machine design, meaning engineers can assist mine operators with virtual twins from the early stages, as well as during virtual commissioning and live operation.\u201d<\/p>\n\n\n\n

When it comes to capturing data for a performance digital twin, process control systems and manufacturing operations management (MOM) are the primary sources to consider, according to the Siemens expert. This performance twin is created using the real production systems and is enriched with IoT data, enabling the optimization of production and service-critical equipment.<\/p>\n\n\n\n

\u201cIntegrated working processes help ensure that a digital twin, once it has been created, is kept up to date over the remaining service life of the plant, thereby keeping the cycle between virtual and real production running without interruption,\u201d Walther continued. \u201cAll of that, as well as the simulation of optimization scenarios and future plant designs, assists mine operators in optimizing the performance of their plants and optimally integrating their supply chains. Even suppliers and intralogistics can be integrated when using an end-to-end collaboration platform.\u201d<\/p>\n\n\n\n

Ultimately, however, success rests on the quality of data available. For Schoone, this is the \u201ckey expertise the mining industry is searching for,\u201d noting that conversations with mining companies often start by discussing the latest AI or digital twin technology but usually end up focusing on data infrastructure. \u201cThe \u2018aha\u2019 moment comes when the mining operation realizes the foundation is proper data handling,\u201d Schoone concluded. \u201cOnly after realizing this can you progress and add real value with the advanced digital tools available today.\u201d<\/p>\n\n\n

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\"A
A mining operation that aggregates all data along the material value chain into a single point of truth can optimize in multiple directions simultaneously. Image: Innomotics.
<\/strong><\/figcaption><\/figure>\n<\/div>\n\n\n

Managing the transition<\/strong>
In addition to interoperability and data quality, several other challenges arise when implementing the intelligent mine, including technological, financial, and regulatory hurdles. However, it is organizational challenges that loom largest for Schoone, who noted that digitalization is not just about downloading an app. \u201cIt is more about transforming working processes into digital processes and having that change accepted by the user.\u201d<\/p>\n\n\n\n

As industries navigate shifting market demands and technological disruption, it has become clear that digitalization is essential for companies determined to stay competitive in the long run.<\/p>\n\n\n\n

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\u201cAcross industries like mining and mineral processing, digitalization is redefining what operational excellence looks like,\u201d the Innomotics expert continued.<\/p>\n<\/blockquote>\n\n\n\n

\u201cWe see firsthand how intelligent drive systems, connected assets, and advanced analytics create measurable efficiencies and open new pathways for innovation. With the right expertise and commitment, digital transformation is not only achievable \u2013 it\u2019s how the industry engineers its next leap forward.\u201d<\/p>\n\n\n\n

A significant part of managing the intelligent mine transition will be the changing role of the human operator, which will shift from \u201cmanual labor and routine operations to more strategic, technical, and oversight responsibilities, such as system oversight, data analysis, compliance, and training,\u201d EYEMINE\u2019s de Kock said. According to Schoone, this will likely involve teams of remote engineers who can interpret and utilize digital systems, data-based analyses, and the physical and chemical processes of mining to transform information into real-world action. However, although their roles will change, \u201chumans will continue to play a key role in the future of mining,\u201d the Innomotics expert concluded.<\/p>\n\n\n\n

There is also an opportunity here, as Siemens\u2019 Walther argued, who pointed out that \u201cachieving a sustainable economy also means creating long-term and attractive mining jobs.\u201d With mining traditionally facing an image problem in attracting talent, digitalization could help change attitudes, making it more appealing to younger individuals. \u201cWhen processes are digitalized, staff can access all systems remotely, saving them from long travel times to work in a dirty, dusty, and dangerous environment,\u201d Walther said.<\/p>\n\n\n\n

Lastly, but by no means least, we must consider cybersecurity, especially as industrial cyber incidents become more frequent.<\/p>\n\n\n\n

As mining operations increasingly rely on technology, cybersecurity will transition from a technical protection issue to one of business continuity and resilience.<\/p>\n\n\n\n

In Schoone\u2019s opinion, managing the cyber risk should therefore be included in the operating costs of a digital system with cybersecurity systems \u201cconstantly optimized and developed to avoid unpleasant surprises.\u201d<\/p>\n\n\n\n

Envisioning the future<\/strong>
\u201cWe are moving toward fully automated and autonomous systems,\u201d Siemens\u2019 Walther said, a conclusion that both Schoone and de Kock agreed with. This shift is happening along a spectrum from local, machine-based operation to fully automated, autonomously operating mines, with a small team onsite to oversee the plant, conduct maintenance, and undertake urgent work (although, even this onsite team will be assisted by intelligent robots and drones, added Schoone). When you reach that stage, \u201cyour mine has undergone a complete digital transformation into an intelligent mine,\u201d concluded Walther.<\/p>\n","protected":false},"excerpt":{"rendered":"

With innovative, digital technologies proliferating in mining, an intelligent future beckons. by Jonathan Rowland The global pressures mining operations face will be familiar to readers of North American Mining. The increasing demand for critical minerals, along with diminishing ore grades, tightening environmental expectations, the need for safer workplaces and skilled personnel, and fluctuating commodity markets, all place demands on this…<\/p>\n","protected":false},"author":8,"featured_media":11481,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"om_disable_all_campaigns":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_themeisle_gutenberg_block_has_review":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":false,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2},"jetpack_post_was_ever_published":false},"categories":[4],"tags":[4207,4209,4208,4210,614],"coauthors":[1635],"class_list":["post-11480","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features","tag-eyemine","tag-information-technology","tag-intelligent-mining","tag-intelligent-robots","tag-mining-operations"],"aioseo_notices":[],"aioseo_head":"\n\t\t\n\t\n\t\n\t\n\t\n\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t