Technologies like autonomous drill systems are at work across our mines, tackling some of our biggest challenges and transforming the way we source, mine, process, move and market our products.
FutureSmart MiningTM is Anglo American’s innovation-led approach to sustainable mining. A blueprint for the future of our business, it defines how innovative thinking, enabling technologies and collaboration are helping us shape an industry to become more sustainable, more efficient and safer – transforming the way we work, while removing people from harm’s way.
ADS control desk
The introduction of autonomous drilling systems (ADS) is one such example. These systems, which allow operators to move from sitting inside the drill rig to a state-of-the-art control centre, are bringing several advantages to our operations, including:
- Improved safety: Automation of certain processes reduces workers’ exposure to potential incidents and harmful conditions, including machine vibrations, noise and dust. As well as physically removing employees from harm’s way, ADS also contribute to improving mental wellbeing by reducing or removing psychological hazards like workload, long working hours and isolated work.
- Productivity gains: The accuracy, efficiency and consistency provided by automation can improve productivity, particularly during occasions such as shift changes, lunch breaks or during blast clearances, where automated equipment can continue to operate. The ADS we are deploying have the potential to deliver an average 15% improvement in productivity across our operations.
Joining Anglo American as Head of Mine Modernisation in February 2021 with more than 30 years’ experience as a mining engineer, Alastair Mathias has spent the past decade exploring how innovative machines, process automation, and data and analytics can combine to fundamentally reshape the industry, with safety improvements a firm priority.
Alastair said: “The reality is that mining, in one form or another, involves the breaking of rock and the processes involved in that have inherent risks. So, the single best thing we can do to improve safety is to remove people from those environments.”
Computer generated view from a virtual drill training
There are other benefits too, from productivity gains to the ability to drill more accurately and consistently, which improves fragmentation, and the efficiency of loading and processing. “While there is significant upfront configuration required to establish ADS”, Alastair added, “once this has been completed it can run entirely independently for extended periods over multiple holes. The benefit is that one operator using a single console can realistically control several autonomous drill rigs simultaneously.”
Since deploying our first fully autonomous drill in the second quarter of 2021 – used to make a 16m hole in under 15 minutes – we now have 31 systems operating globally, including at Sishen, Kolomela (iron ore) Mogalakwena (platinum group metals) in South Africa; Dawson, Australia (steelmaking coal); Los Bronces, Chile and Quellaveco, Peru (copper). Between them, these systems have drilled more than 6.5 million metres; with that number set to increase over the next 18 months as Anglo American executes on plans to grow its fleet to more than 50 units.
Explaining further the advantages of employing ADS, Alastair said: “We also see an opportunity for the drill to be used as a sensor, rather than for simply making holes in the ground. This matters because everything in mining comes down to orebody knowledge. If we improve our understanding of the asset, we can reduce variability, installed capital, stockpiles and any other factors leading to uncertainty. We can mine in the most efficient and effective way possible.
“One concept I’ve seen discussed for a few years is zero entry mining, which relies entirely on machine operations on site and removes the need for human entry into a mine. This falls over quite quickly because at some point there will be a need to maintain and service the equipment. What we can do is to dramatically reduce peoples’ exposure. Drilling is noisy - it can create dust and operators are exposed to vibration. There is also risk involved in driving in and out of the mine. With automation, we can take many of those hazards away.”
What about the potential for automation to displace jobs? Alastair said: “The thing with automation is that it doesn’t happen by magic. There is a big support staff that sits around it. Roles may change, but they don’t necessarily disappear, particularly in drilling. We will still need people in the field because drills have sensors, and those sensors need to be serviced and calibrated regularly.
“The advantage with the new roles that are arising is that they are likely to be more highly-skilled and can be done remotely. Which means automation has a big impact not just on physical health but on mental wellbeing too, because in many cases, operators can work closer to home, rather than at the drill site, and hence be more readily available to their friends and families.”
To help our teams transition to new ways of working, we have created a bespoke training programme, designed to quickly upskill controllers and maintenance employees. Enhancing their capabilities will open a range of opportunities to them as our mines become increasingly technologically advanced.
Alastair said: “It’s important to transition our already skilled people to new ways of working so we can deliver materially improved safety and productivity. We’re not training operators how to run a drill; they already know how to do that. Instead, we are training them to work in a completely different way where they can operate multiple drills remotely. It’s about safety and efficiency because, ultimately, something cannot be efficient if it’s not safe.”
Drill rig operator, Janice Willemse, has worked in the mining industry for 12 years. She used to work on board the drill rig, but her role has been transformed by the introduction of ADS. She said: “In the past, we would have some days that ran smoothly, and others where you might be more exposed to the elements, like heat and dust. Using ADS and operating the machine from a control centre feels much safer and less exposed. The investment the company is making in upskilling us as operators is very good, considering the fast pace at which the world and environment around us are changing.”
Fellow drill controller, Olebogeng Fossie Masigo, has worked for Kumba Iron Ore for 11 years, and is excited about the technology’s potential to help ensure the quality and consistency of blast holes being drilled. He said: “The job of a drill controller is challenging, with a lot of noise and vibrations when operating the machine. The accuracy and speed with which the new system performs is astonishing, and I am pleased that this knowledge is being transferred to me, and that I am getting help to become an expert in autonomous drilling. I enjoy being part of this group. The technology and the way we are operating is very interesting, and working in an environment like the control centre is very nice because I feel more comfortable, and safer to return home to my family.”
Also key to successful deployment has been a strong partnership between the mining operation, Anglo American’s mine modernisation team and the equipment supplier.
ADS is not the only technology innovation being embraced by Anglo American. Improvements in geospatial data are helping us gain greater insights into mine systems, while the use of smart data and machine learning are improving operational efficiency, safety and productivity. And according to Alastair, the mine of the future will look even more radically different than it does today.
“Automation can be a dangerous word,” he said, “because it means many things to many people. Automation, autonomy - people broadly tend to think of this as big trucks, big drills, machine automation and robots. In fact, there is an enormous opportunity in the automation of process and workflow too.
“What I mean by this is data-driven improvement, where our goals might start to include things like ‘how do we minimise water usage?’, ‘how do we minimise energy use?’. So, not just production goals, but bringing the whole aspect of sustainability under the lens and into focus.”
A drill operator working from a central control room, rather than
onboard the drilling rig
While advances in technology will play an important role in shaping the future of mining, our investment in reskilling and upskilling employees to meet the evolving expertise and capabilities they need for the tasks they are performing is just as important.
As Alastair concludes: “The reality is, we must mine differently. No one likes the traditional view of mining but, at the same time, everyone wants an electric car. There is a range of skillsets – from mechatronics to software engineering to data science – that can be brought to bear to solve the challenges we are facing, both as an industry and as society more broadly.
“By showing up as a more digitally sophisticated mining company; one that approaches the problem of meeting and exceeding challenges like climate change or the need for more sustainable communities, there is an opportunity to truly differentiate ourselves.”