As the mining industry embraces industry 5.0, the implementation of digital twins emerges as a game-changer, promising significant advancements in efficiency, productivity, and safety.
1. Digital twins in mining unlock a potential 10-20% productivity leap.
2. Automation reshapes worker risk profiles in mining operations.
3. Tech-driven mining leads to a smaller environmental footprint.
Predictive maintenance
The mining industry widely uses time based maintenance strategies.
Repair or replacement is based on fixed time intervals irrespective of the condition of the equipment, leading to parts being replaced before end of life and higher amounts of asset downtime.
Digital twins provide the ability to shift towards a predictive maintenance strategy based on asset health. Which could potentially result in-
a. Increase in asset operating time of 7% – 15%.
b. Improvement in productivity from 15% to 20%.
c. Improved safety – increasing levels of automation and remote operations will further reduce exposure of employees to hazardous environments.
Integrated plan
Optimization Giant: With digital twin modeling, scheduling can be optimized, stockpile reliance reduced as well as throughputs being boosted by 10%-15%.
Data-Based Decisions: Integrated advanced analytics enable simulation for optimal strategies, enhancing production, cost efficiency and sustainability.
Transport
Reliable transportation is crucial for mining operations, as breakdowns can halt activities, leading to missed shipments and downstream impacts. Effective maintenance practices, leveraging digital twins, enable predictive maintenance, broken rail detection which helps minimize interruptions and derailments while merging engineering, operations, and IT for proactive issue resolution and decision support.
a. Automating trains can extend operating hours by up to 20%.
b. Predictive maintenance cuts asset downtime by 20%-35%.
c. Optimized ship loading reduces missed shipments.
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