(Reuters) - In an
office trailer parked outside a mine shaft in northern Ontario,
operator Carolyn St-Jean leans back in her chair and monitors a machine
loading nickel-rich ore into rail cars deep underground.
Once filled, the automated
train will snake through a series of narrow tunnels, emerge from a rocky
outcropping, then loop past St-Jean's window and dump its payload for
sorting.
Vale SA, the Brazilian
company that owns the mine near this nickel-rich Canadian town, has
spent nearly $50 million in two years to install and test the
"rail-veyor." The company believes the transport system will
revolutionize how it builds and extracts new mineral deposits.
The
equipment is made locally by Rail-Veyor Technologies Global Inc. It is
one of many mining technologies that developers hope will allow future
production to be run almost entirely by people safely above ground.
Such advances may prove crucial as easy-to-exploit deposits run dry and miners drill deeper in more remote places to supply China,
India and other emerging economies. The technology could make mining
cheaper and safer, avoiding the need to dig wide tunnels and hire large
numbers of expensive, skilled workers.
"As
we go deeper, if we continue to apply existing thinking and existing
technologies, it's a death spiral" for company profits, said Alex
Henderson, who heads Vale's technology team in Sudbury.
"We need to begin to look at a step-change in mining rather than just incrementally improving our existing processes."
The
rail-veyor is one such step-change. At the test site, it has halved the
time to build a mine, and Vale expects a 150 percent boost in
production rates before year end.
In Australia,
Rio Tinto Ltd, one of the world's largest miners and an automation
pioneer, is rolling out a fleet of self-driving trucks and trains at its
iron ore operations. Vale, BHP Billiton and Chile's Codelco are in hot
pursuit.
Gold miner AngloGold
Ashanti is eyeing automation in South Africa, where miners spend hours
each shift traveling up and down shafts and ounces of gold are left
behind in support pillars each year.
Organized
labor has made its peace with the automation drive, although there were
some concerns that robots would displace humans.
"We're
ok with automation, it's part of the changing times and it's a good
thing for productivity," said Myles Sullivan of the United Steelworkers
Canada, whose workers ended a year-long strike at Vale over bonuses and
wages in 2010.
700 STORIES UNDERGROUND
New
challenges in mining are driving technological changes. Large,
accessible deposits have all but disappeared. Resources of tomorrow are
in far-flung corners of the globe or hundreds of meters beneath the
surface.
Add a shortage of skilled labor - expected to worsen as the baby-boom generation retires - and mining costs have surged.
While
soaring demand means higher metal prices, rising costs are crimping
profits. Canada's S&P/TSX Mining share index has fallen more than 38
percent since the beginning of 2011.
Experts say mining companies must change how they operate.
Making
that shift is not easy for an industry steeped in tradition, especially
when change doesn't come cheap. Rio Tinto is spending more than $500
million on train automation alone.
"This
is a very conservative industry that has been very productive over the
last 30 years doing it the way they're doing it now," said Douglas
Morrison, chief executive of the Centre for Excellence in Mining
Innovation (CEMI), an industry-funded research center in Sudbury.
"But is the old way going to work for us into the future? I think probably not, so we need to make some changes."
After
decades of production, the nickel mines around Sudbury are getting
deeper and deeper. At Vale's Creighton mine, the No. 8 shaft drops
nearly 8,000 feet into the ground - equivalent of a 700-story condo
tower.
At that depth it is very
hot, around 50 degrees Celsius (120 Fahrenheit), so tunnels must be
pumped full of cooled air to make temperatures manageable for people and
heavy machinery.
"The bigger issue
is when we get much deeper we start to generate our own earthquakes -
very small earthquakes - these are called 'rock bursts,'" said Morrison.
Smaller
tunnels and new ways of digging can hopefully reduce the danger of
these rock bursts, which create a safety concern and slow development.
Rio
Tinto is working with CEMI on automated tunnel borers, currently used
to build subway and sewer tunnels. By cutting through the rock instead
of blasting, Rio aims to quadruple its underground advance rates to 20
meters a day.
But while automated
tunnel borers will build shafts and tunnels more quickly, massive mining
equipment still handicaps the industry, which is where Vale's
rail-veyor comes in.
A train
hauling 50 tonnes of ore uses a far smaller tunnel than a truck with the
same load. By taking the massive trucks and scooptrams - large vehicles
with shovels on the front - out of the equation, Vale can build more
compact and stable tunnels.
The
rail-veyor, built on tracks that zig-zag down to the deposit, actually
eliminates the need for expensive shafts and may eventually move people
and equipment, along with ore.
Vale's
Henderson believes the technology - which the company plans to roll out
in five upcoming projects - is a game-changer that will help usher in a
new era of mining.
"Just as the scooptram was the key enabler for the mechanized era, is the rail-veyor a key enabler for the next?" he said.
MAN VS MACHINE
What
that "next era" will look like is still up for debate. Some innovators
believe robots will do most of the labor in mines of the future, as in
automobile assembly plants. This would ease likely shortages in skilled
labor in many countries.
Over the
next decade Canada's mining sector will need more than 100,000 skilled
new hires to sustain even modest growth, according to the Mining
Industry Human Resources Council.
In
Australia, the labor crunch is already so intense that truck drivers
can make upwards of $100,000 a year, with turnover rates at some mines
still near 40 percent.
"One of the
biggest problems that the mining industry faces worldwide is trained
personnel. We can't get them," said John Meech, director of CERM3, a
mining research center at the University of British Columbia in
Vancouver.
"One of the ways we are
going to have to deal with that is to automate the systems so that the
human becomes the supervisor, rather than the direct means of control."
It
is a concept already used at remote open-pit mines in Australia, where
Rio's new fleet of driverless trucks can be run from a control room
hundreds of miles away.
Canada's
Nautilus Minerals Inc is using automated rovers to explore the ocean bed
for mineral deposits that underwater robots will eventually mine.
In
addition to boosting productivity, the advances will enhance safety. As
labor leader Sullivan says, "so long as there's underground mining,
there will be women and men working underground."
Safety
is the focus at a converted schoolyard just outside Sudbury, where a
duo of mine rescue robots roll through a makeshift obstacle course.
Their thick tires grind over logs and through mud pits.
Designed
by Canada's Penguin Automated Systems Inc, the equipment is being
tested by Codelco at its Andina copper mine in Chile, doing dangerous
jobs like checking stability after blasting and surveying tunnels at
risk of flooding.
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