Mining’s digital evolution: Delivering technology for safety and sustainability

Matthew Wakeford, Automation Superintendent

Anglo American

Mining has transformed remarkably from the era of picks and hammers to a future that uses cutting-edge technology to enhance safety and operational efficiency.

As a long-time leader in safety innovation, the modern mining sector has led the charge to significantly advance autonomous operations. The rapid pace of technological innovation – especially in areas like data analytics, automation and digitalisation – unlocks incredible opportunities for the mining sector to become safer, more productive and more sustainable.

At Anglo American, we have re-imagined mines where our people can remotely manage operations from a safe distance, using real-time data to make informed decisions.

This paradigm shift has not only enhanced safety for our people but also delivered significant improvements in operational stability and production predictability for our customers.

Before Anglo American’s steelmaking coal operations in Australia began their focus on autonomous mining in the 2010s, only one known mine globally had achieved sustainable remote operations - San Juan Mine in the United States.

In 2024, our 10-year vision for a ‘mine of the future’ became reality when all three underground coal mines in Australia began operating simultaneously from our Remote Operation Centres (ROCs).

By September of the same year, our underground operations reached another significant milestone, notching up 10,000 longwall mining shears from our ROCs. Since transitioning to remote operations, we have reduced exposure risk to hazardous areas by 22,500 hours across our five Bowen Basin mine sites.

This shift to ROCs marks the culmination of a challenging decade-long journey – one that, at times, seemed impossible. Each advancement towards our vision introduced new obstacles, requiring the development of further technology capable of meeting the unique demands.

But a group of dedicated visionaries –determined to overcome the challenges each new innovation presented – led the charge. Innovation alone, though, was not enough. Our core values of safety and collaboration were also key to success.

Our people

Those at the forefront of this transformation took everyone on the journey – from our workers at the coalface to upper management. Sustainability became the key to long-term success. New capabilities hold no value if they cannot be maintained over time.

By empowering our people to evolve alongside the industry, we have ensured the legacy of expertise remains an indispensable cornerstone of success. Through extensive trial and error, we have refined our processes within a mining environment. Our teams have integrated systems and automation to support sustainable ROC functions while preserving decades of expertise from our skilled people on the ground.

We have also standardised our equipment, technology, systems and software selection, enabling our teams to apply insights gained from one mine to another.

Longwall automation

These strategic moves have eliminated the need for human presence in potentially hazardous underground environments, marking a significant step toward minimising coalface exposure hours.

Aquila Mine, near Middlemount, was the first to achieve a full year of shears completed 100% from the ROC, cementing a remarkable shift toward remote control not seen before in the Australian coal mining industry. The mine was able to reach more than 42% ROC operation during its first longwall panel and has since achieved more than 98% ROC shears on subsequent longwall panels.

Key success factors include:

• Reducing exposure to potential occupational hazards: By operating the longwall from an office environment rather than underground at the coalface, operational coal mine workers are removed from hazardous underground environments.

• Improved ergonomics: Operators can work in a comfortable and ergonomic environment, reducing the likelihood of musculoskeletal injuries that can occur in traditional mining settings.

• Emergency response: The ROC has advanced monitoring and communication systems that allow operators to respond to any potential safety issue.

• Real time monitoring: The ROC has advanced technology and monitoring capabilities, including for gas levels. It adjusts shearer speeds to allow ventilation to move and dilute any increase in gas.

• Reduced exposure to harmful substances: The longwall ROCs have reduced operator exposure to respirable dust hazards, thus minimising the risk of respiratory issues and other health problems.

• Data-driven decision-making: The longwall ROC gathers extensive data on mining operations, which can be analysed to identify patterns and trends related to safety. This data-driven approach enables personnel to make informed decisions to enhance safety practices and prevent incidents.

• Continuous improvement: The remote operating environment allows for continuous improvement of safety practices. Lessons learned from incidents or near misses can be quickly incorporated into operating procedures and shared across multiple locations.

With a vision that emphasises the seamless transition of skills, we are not only embracing automation but also nurturing the expertise of our workforce for the future.

Achieving autonomous mining presents unique challenges, particularly in managing exceptional situations that occur outside of normal operating conditions. Issues such as maintenance, blockages, geological anomalies and strata challenges create an opportunity to further develop systems capable of seamlessly navigating through all operating conditions.

Our dedication to this endeavour stems from the understanding that the more resilience we build into our automation systems, the less human intervention will be required. This approach not only reduces operational exposure but also significantly strengthens the stability of the longwall system.

Global industry-first initiatives to enable remote operation include:

• Autonomous Shearer

• Shearer Auto Duck: Prevents need for manual shearer operation during cavity events and after maintenance.

• Auto Gate Road Entry: Removes need to manually operate shearer when entering a gate end roadway.

• Seam Steering: Ability to steer and control the horizon of the shearer from a remote position.

• Integrated Face and Camera Control System

• Cavity Management System: Enables Powered Roof Support (PRS) automation during cavity events.

• Personnel Proximity Detection: PRS and Roadway

• ROC Management System

In total, more than 1,000 Original Equipment Manufacturer (OEM) system initiatives have enabled remote operation success. However, the knowledge and experience of traditional shearer operators continue to play a pivotal role in the operation of our mines. They are the irreplaceable subject matter experts with an unparalleled understanding of health and safety within the mining environment. They play an integral role in shaping the industry's future trajectory, helping to train and update our automation models and validate edge-case scenarios. The coal miners of today will continue to be the coal miners of tomorrow.

Personal Proximity Detection systems

Effective automation also requires effective process solutions facilitating integration between people and machine. Our Personal Proximity Detection (PPD) systems enhance safety for our people when they are operating near or with machines in our complex longwall and development panel environments underground. Through extensive collaboration with our workforce and industry partners, all three Anglo American underground mines now use PPD to protect our people on the longwall face, manage coalface times and integrate dust control measures.

Longwall PPD has become a key enabler of successful remote surface operations, which has achieved sustainability at our Aquila, Grosvenor and Moranbah North mines this year, reducing exposure to PRS and roadway push hazards. During operation, our people wear PPD tags integrated into existing cap lamp technology, allowing for precise identification of their positions within the mine as an additional protection.

The system alerts workers if they are detected in the vicinity of a transitioning PRS or a moving shuttle car, enabling surface operators to halt movement until all people are at a safe distance. The use of PPD, combined with real-time dust monitoring, has provided a better understanding of dust exposure locations, and positional data allows leaders to implement operational and behavioural controls if required.

Anglo American’s PPD program is succeeding through effective change management, comprehensive training and support for our people, strong partnerships, a collaborative approach to design, procurement, delivery and continuous improvement, as well as leadership that places safety at the heart of everything we do.

Tele-remote dozers

Anglo American has also made significant strides in safety through automation innovation that eliminates the need for operators to be physically present in stockpile dozers.

Hidden voids in coal stockpiles at Coal Handling and Preparation Plants can create hazardous unstable ground conditions but this new technology significantly reduces the risks associated with rollover incidents.

Resources Safety and Health Queensland issued safety alerts in 2022 and 2023 after multiple dozer incidents in a short period across the industry, further underscoring the severity of stockpile void hazards.

Addressing these safety concerns has become crucial for protecting operators and preventing potential accidents or fatalities in the future.

Our innovative pilot program involved retrofitting a Komatsu 475-A dozer with a universal tele-remote system, allowing operators to control the machine from a safe, remote location. The project aims to achieve a notable reduction in accidents and injuries, improve operator well-being and productivity, and enhance operational flexibility across a diverse fleet of dozers.

Our Capcoal Complex, near Middlemount, has been trialling a remote-controlled stockpile dozer as part of plans to retro-fit the entire fleet. Once the technology is fully deployed across all sites, we will reduce in-cab dozer exposure time by 45,000 to 75,000 hours a year.

Key innovations – such as advanced joystick control, sound and vision aids, a tilting footrest, and the establishment of safe, dust-free ROCs – have played a pivotal role in fostering a culture of safety and operational excellence. One of the standout features of the tele-remote dozer solution is its agnostic nature, which allows it to be compatible with various equipment types in the Australian fleet.

Global firsts

Mining is entering a promising new era, embracing automation and innovation like never before.

The measurable success of Anglo American's remote longwall operations highlights a groundbreaking shift that dramatically reduces on-site personnel exposure to hazards while maintaining, and even enhancing, operational efficiency. If we are to unlock the full potential of these advancements, we must consistently integrate the seasoned expertise of our workforce — those who have deeply understood and mastered the complexities of coal mining through decades of experience.

By developing state-of-the-art technologies and prioritising the well-being of our workforce through a collaborative approach, our steelmaking coal mines in Australia have emerged as leaders in the industry, reshaping the future of underground coal mining on a global scale.

Our people are irreplaceable, and we are equipping them to grow with the industry, preserving a legacy of knowledge that will always be essential to our success. 