Digital integration in mining: from engineering to operations

The mining industry has entered a period of unprecedented demand — a time of significant challenges, but also vast opportunity.

As the world races towards net zero, advanced technologies like electric vehicles and battery storage are driving soaring demand for critical metals — including lithium, copper, cobalt and nickel. These systems require far more raw materials than traditional energy infrastructure. We are now seeing companies reliant on these metals expand their supply chains and invest directly in mining, such as Apple’s recent announcement to invest in MP Materials.

For mine operators, this surge in demand might seem like a good problem to have. But the reality is more complex: bringing a new mine online can take more than 15 years, and existing sites are already struggling to keep pace. At the same time, projects are becoming more remote and technologically complex. From engineering to operations, a global talent shortage is making it harder to scale at the pace the market demands.

The industry is also contending with rising costs — from energy and labour to equipment and transport. Add to that a difficult global supply chain environment and ESG compliance pressures, and the result is growing uncertainty around delivery timelines and long-term capital planning.

In short, the sector is under intense pressure to deliver more critical metals — quickly and sustainably. It’s no small ask.

The path forward: digitally transforming mine development

To build more mines on time — and responsibly — owner-operators and EPCs are turning to full-scale digital engineering platforms.

Powered by cloud-based design tools, AI-driven modelling and real-time collaboration environments, these systems enable companies to streamline and optimise every phase of mine development — from design and build, commissioning and handover to operations.

This full-spectrum visibility offers a practical solution to the sector’s long lead times and often spiralling costs in a number of ways.

Reduced risk

Digital engineering platforms enhance cost forecasting accuracy, enabling EPCs and owner-operators to run multiple build-out scenarios with varying inputs and constraints. This results in better capital allocation decisions and fewer financial overruns.

According to McKinsey, mining companies that deploy advanced digital technologies and analytics can reduce CAPEX by up to 20% and cut project delivery times by up to 30%.

Reusable designs

Standardised digital solutions allow mining companies to create reusable design templates that can be replicated across multiple projects. This means engineers don’t have to start from scratch every time, enabling faster project iteration, less rework, lower costs and more predictable outcomes. This process allows mining operators and EPCs to work together seamlessly and with smoother handovers.

Integrated project delivery

These types of digital platforms connect cross-functional teams — from engineers and suppliers to construction crews — across a shared data environment. When one team updates a design spec, the change flows across the system. This eliminates version conflicts and ensures everyone is working off a single source of truth.

By ensuring that all stakeholders have access to accurate, real-time design models, companies can streamline handovers and maximise asset performance. But digital delivery is only as strong as the partnership between projects and operations. To unlock lasting value, both must evolve their digital capabilities in tandem.

Projects should deliver a rich, robust digital asset — not just a handover file — containing everything operations will need for decades to come. In turn, operations must be equipped to exploit that asset’s full potential, safeguard its integrity and invest in its upkeep.

Digital mining in action

Global mining firms are already achieving measurable gains through digital-first design and build.

For example, Rio Tinto deployed a suite of digital tools to drive greater efficiency, transparency and control across mine development projects. One of its most significant advancements has been the shift towards design reuse. For the first time, an entire crushing facility, including conveyor systems, was replicated from one project to another — significantly reducing engineering time and capital expenditure.

Another case in point is K+S Potash Canada, which sought to simplify access to design and engineering information to enable global remote collaboration without the need to mobilise office staff. Its projects often involve eight to nine offices and multiple third-party providers spread across different locations. Data was sourced from various systems and formats, leading to inconsistencies and compatibility issues across engineering, procurement and construction disciplines.

By implementing a unified data environment, K+S Potash eliminated errors in raw data and unlocked access to over 10 times more data points. A single source of truth has reduced miscommunication and rework, making handovers smoother and more consistent across the board.

The ability to update data seamlessly within a collaborative environment also ensures all stakeholders have access to the latest insights in real time —  enhancing decision-making and operational agility.

Speed without compromise

The critical metals boom is creating unprecedented pressure to move from discovery to production at breakneck speed. In this climate, mining operators that leverage digital tools and integrated data environments will be able to support rapid scale-up without sacrificing quality or compliance.

Unquestionably, the future of mining project delivery lies in close, digitally enabled collaboration between owners, EPCs, OEMs and regulators. By connecting every phase of a project within a single digital ecosystem, companies can unlock new levels of efficiency, transparency and agility.

This integrated approach shortens the path from groundbreaking to production, cutting the time, cost and risk of building a new mine.

As the sector faces growing pressures to produce more with less, those who embrace fully integrated digital engineering will lead the next generation of mining companies.

Image credit: iStock.com/annavaczi