Mining Connectivity: The Crucial Role of Private Networks in Digital Transformation

The mining industry is rapidly embracing automation and integrating digital technologies across its operations. All these transformative digital applications require critical network connectivity for operational efficiency, and given the nature of mining activities, wireless mobile communications are essential.

Exploration and Prospecting

Modern mineral exploration relies on geophysical and geochemical technologies that analyze soil, rock, water, vegetation, and vapor. Technologies such as tomographic imaging, laser and X-ray fluorescence, near-surface seismic imaging, and aeromagnetic surveys using drones generate vast amounts of data.

Field operations often take place in remote areas with limited communication network coverage. Prospectors and field engineers are forced to carry laptops, hard drives, and USB keys to collect, transport, and deliver data.

A reliable alternative to address these challenges is a deployable LTE-based solution from Nokia, which incorporates carrier-grade Nokia Flexi Zone small cells and integrated core technology. Combined with a satellite link or a microwave link at the base camp, this solution can provide high-bandwidth mobile connectivity even in the most remote locations, enabling data collection from sensors and field equipment while also giving field workers access to remote data and remote processing capabilities.

Additionally, the initial network can be easily expanded as field operations grow, supporting the mine from its early stages to full-scale operations.

Automated Drilling and Blasting

In the Kiruna mine, in northern Sweden, for example, remotely operated electric drill rigs are used alongside automated ore-handling equipment. Remote operators control three drill rigs simultaneously, assisted by mapping software to execute precision blasting. After the explosion, automated loading, hauling, and dumping machines transport the extracted ore to load automated trains.

At Rio Tinto’s Pilbara operations in Western Australia, 20 automated drill rigs are in use. A single operator, located nearly 2,500 km away in Perth, controls four drill rigs simultaneously and oversees key points of the process. The drill holes are executed in a predefined sequence based on locations and depths programmed into the system. This enables much greater precision and nearly continuous operation. Over the course of a year, these automated drill rigs operated an average of 1,000 more hours per rig than conventional drill rigs.

In all cases, industrial wireless technology is essential for video surveillance, sensor data collection, and the remote software coordination of drill rigs and drilling operations. This precise coordination of equipment through software reduces drilling cycle times and enhances the safety of both machinery and personnel. Drill data is also analyzed remotely to dynamically adjust the blasting process, aiming to improve both safety and efficiency.

Automated and Remote Operation for Loading, Hauling, and Train Systems

In January 2019, Komatsu announced that its FrontRunner Autonomous Haulage System (AHS) had been enabled to operate with private LTE in commercial operations, paving the way for an ultra-reliable and secure system. The company completed a year-long pilot testing program.

At the end of 2017, Caterpillar reported having 100 autonomous trucks operating across three continents. The largest fleet, consisting of 54 autonomous trucks, achieved a 20% increase in productivity.

The loading of trucks and train wagons can be either partially or fully automated. Key moments in the loading process may, for example, require operator supervision and intervention. Employees can work in a more comfortable and safer environment, without exposure to health or safety risks. Remote machine control can be seamlessly transferred to other operators in real time, ensuring continuous machine operation even during operator breaks.

Worker Safety and Mission-Critical Communications

Personal protective equipment (PPE) is the last line of defense for workers. Traditionally, this includes items such as helmets, earmuffs, masks, and steel-toe boots. However, today, smart technologies are being integrated into PPE.

This new class of equipment includes integrated communications in earmuffs and helmets, display screens, and built-in environmental sensors to monitor heat, noise, and exposure to chemicals and gases. Smart PPE can also be used alongside LTE-based geofenced applications to alert miners when they enter restricted areas.

Situational Awareness to Prevent Accidents

Situational awareness through video coverage and mass detection is key to ensuring the safety and sustainability of future mining operations and personnel.

To achieve a 360-degree understanding of the situation, the wireless network must be capable of meeting the high bandwidth demands of video cameras across the entire coverage area, including mines, railways, and ports. Many of these cameras may be mounted on mobile vehicles or drones.

Predictive Maintenance Through IoT and Analytics

Maintenance and repair of mining equipment present challenges in planning equipment usage. Breakdowns and unplanned maintenance of aging assets can cause significant disruptions.

Predictive maintenance applications leverage LTE's extensive coverage to collect data from Internet of Things (IoT) sensors across the mine, feeding into asset management and advanced data systems. Having all critical mining operations run on the same private LTE network helps unify large, isolated data streams, maximizing the benefits of analytics engines.

The General Advantages of Private LTE

Mining operation decision-makers often evaluate the advantages of different technologies based on specific use cases. In addition to the specific applications we reviewed, we can highlight the overall benefits that a private LTE network brings to the entire mine.

Any application requiring wireless connectivity—and even some that could be served by a wired connection—can be addressed with 4.9G/LTE and 5G technology. This is because LTE and 5G have the capacity to handle the necessary bandwidth for powering HDTV cameras while also supporting low-power sensor and IoT networks.

Both LTE and 5G are as reliable as a dedicated wired network but far more flexible. Through network segmentation, a single LTE or 5G network can support multiple applications with dedicated resources and quality of service, configured with specific parameters for each use case.