Digital solutions enhance productivity, efficiency, safety

With the advent of Industry 4.0 and increasing levels of digitalisation being pursued by mining operations, automation technology company Siemens says digital transformation will continue to be sought and adopted by mining companies seeking operational efficiency, improved safety and increased profitability.

According to Siemens’ ‘South Africa by 2040 Pictures of Transformation’ report, 35% of mining jobs will be automated by 2035, half will require less human interaction and the workforce will need significant reskilling.

Amid such rapid technological change, the company is positioning its advanced technologies and integrated systems to address the evolving challenges in the mining sector.

With a focus on innovation, sustainability and digitalisation, Siemens is also aligning its offerings to assist mines with an improved ability to achieve environmental, social and governance (ESG) targets.

The company’s various automation and digital solutions offerings ensure that mining organisations can better use data from their assets to improve mining productivity and reduce hazardous manual mining processes, ensuring that such tasks and mining methods can be undertaken using automated or remotely operated solutions.

Efforts to incorporate digitalisation and automation into mining processes will also positively influence sustainable mining targets and efforts to achieve net-zero carbon emissions by 2050.

While the report says most mines “are racing” to meet net-zero targets by 2050, Siemens notes in a statement that this will be a “monumental task”, as it requires an overhaul of almost all mining methods and processes.

In terms of the energy transition and reducing reliance on one power source, the company notes that an increasing number of mines are going off-grid and generating their own power, with a hybrid solution of self-sustained solar plants supplemented by grid power being the option used in most cases.

There is growing demand for on-site electricity generation or independent power production, as many mining operations are located in remote areas, far away from grid infrastructure, says Siemens sub-Saharan Africa CEO Sabine Dall’Omo.

The company also says that its renewable-energy technologies and smart grid solutions align with the industry’s move towards self-generation and using renewable energy to eliminate 73% of Scope 1 and 2 emissions.

The Siemens PSS-Sincal simulation software enables mines to manage multiple sources of power, such as grid power, solar PV, wind or diesel generators.

“Plants want to run their own electricity sources because they have to report back what kind of electricity they used in the operations for the ESG targets,” she adds.

Several major industry players are also exploring green hydrogen to replace diesel, and most have invested in battery energy storage to improve their energy stability during times of generation deficits, according to Siemens.

“In today’s dynamic mining landscape, organisations must stay ahead of the curve. It’s critical to implement solutions that optimise operations, reduce costs and ensure compliance with international standards while prioritising sustainability and safety.”

Siemens’ advanced technologies and integrated systems demonstrate how mining operations across sub-Saharan Africa can become more efficient, productive, cost competitive and sustainable, adds Dall’Omo.

Automation equals Optimised Productivity

Siemens’ automation service offerings provide solutions to overcome challenges regarding mine efficiency and productivity.

Through its digital software, such as digital twin models – virtual models of assets and plants depicting operational performance metrics from physical sensors on the object – the company enables the streamlining of performance information.

This information can be analysed by offsite professionals, enabling them to develop action plans for emerging trends, and to better inform decisions about asset longevity, maintenance and the outcomes of any adjustments thereto.

Digital twins can also improve productivity, lower costs and make operations safer.

Digital twins also enable mines to simulate and optimise processes before implementation. This technology is crucial, as Siemens says experts predict that up to 40% of mines will use digital twins by 2040 to enhance safety, efficiency and decision-making processes.

Automation is also important as mines increasingly look to digital solutions, with the company pointing out that its ‘Pictures of Transformation’ report, published on September 5, forecasts that between 30% and 40% of mining machinery will be autonomous by 2040.

Autonomy solutions help improve safety in harsh environments and increase operational efficiency, according to Siemens.

“If you have a higher level of automation, you have a possibility to actually have a higher output out of your plan and even a higher productivity . . .” says Dall’Omo.

She dispels the popular notion that automation will contribute to extensive job losses in the South African mining sector, saying instead that autonomous mining simply removes people from dangerous mining environments, contributing to the health and safety of workers.