New challenges, new solutions: the role of process automation in the mining industry

Field instrumentation and other process automation technologies are widely used across every process in the mining industries from resource development to mine operation, to rail and port operations. However, the biggest challenge the instrumentation and process automation industries are facing is the shortage of semiconductor chips. Other major political events like the war in Ukraine and the relocation of manufacturing hubs from China due to pandemic uncertainty have disrupted the entire supply chain cycle, which is significantly affecting the industry’s ability to responding to demand within the mining market in Australia.

The focus on ‘net zero’ has increased the demand for base metals. However, base metals like lithium, rare earth, silicon, copper and alumina are not bulk resources like iron ore.

Base metals are discrete and available on very small scales and in patches, hence increasing operational costs. To address this issue, the mining industry’s priority is to focus on remote operation, collecting real-time data, supply chain management, workplace safety and environmental sustainability, which has resulted in promising opportunities for the adoption of Industry 4.0.

Over the last three years we have seen mounting pressure on the process automation industries and accelerating digital transformation. Industry 4.0 will take mining processes — from mine to market — to a whole new level. Industry 4.0 has given a refreshing heartbeat to the challenges within the mining process and has given a new ray of hope for the industry to operate 24/7 without human intervention. This means improved operating efficiency, higher productivity and monitoring of device status and predictive maintenance. Industry 4.0 also promises a high level of IT and data security standards, opening doors for decentralising measuring points, establishing a plant overview, monitoring plant status, running predictive maintenance and mobile asset audits, etc.

However, with every opportunity comes challenges. Currently in Australia, implementing Industry 4.0 in the mining sector is a huge risk until the technology is proven and makes a high impact on small strategic projects. Another challenge is the legacy situation where a transfer from current infrastructure to new infrastructure is needed. There is significant pressure on process automation and instrumentation manufacturers to propose products that can reduce the operation cost due to the high investment in CAPEX projects and low investment in OPEX. In addition, the shortage of Industry 4.0-skilled labour has kept the mining industry on the back foot when it comes to using the latest technology. This issue creates a barrier of uncertainty for the instrumentation and process automation industry to invest in introducing new and refreshing technologies in Australia.

But new challenges come with new solutions, and I’m confident that the instrumentation and process automation industries can overcome these challenges, with proper onboarding of the technology and by beginning with small-scale deployments. The process automation and instrumentation industries not only need to bring the technology that works day in day out, but also need to assess the value proposition and improvement it brings to the business. The instrumentation and process automation industries will have to work very closely with the mining industries to upskill their employees with proper training and development in new technology and make the supply chain more reliable.

*Vikram Apte has a M.SC Instrumentation Degree from the Department of Instrumentation Science, Pune, and an MBA in International Marketing from Griffith University. He is currently working as Industry Manager for Mining, Minerals and Metals, and Oil and Gas at Endress+Hauser Australia.

Image: ©stock.adobe.com/au/Dusko