• Mining is embracing automation and control technologies
• ABB offers an extensive range of technologies designed specifically for mining applications
• As modern mining operations become increasingly energy-intensive, mine design plays a crucial role

ABB showcased a diverse array of solutions During Electra Mining Africa 2024 that cater to multiple industry sectors, but mainly mining, while highlighting key trends shaping the market and how achieving energy efficiency impacts business operations. These evolving priorities are pushing companies toward greater adoption of digitalisation and automation, enabling them to operate more responsibly and resiliently.

Martin van Zyl, Sales Manager for Process Industries at ABB, comments: “Mining companies across South Africa and the broader Southern African region are embracing automation and control technologies. While there may be some caution in advancing beyond already established systems, mining companies, consultants, EPC professionals, and end users in the region are exceptionally open to progress. In fact, they are often quicker than many international counterparts in evaluating and implementing new technologies.”

According to van Zyl, Southern African mining companies have proven to be early adopters of cutting-edge technologies. “Whether it is new sensors or equipment offering smarter insights, many of our customers are eager to test new solutions, prove the concept, and if successful, scale them up for wider implementation,” he adds.

ABB offers an extensive range of technologies designed specifically for mining applications, addressing everything from operational efficiency to sustainability goals. It works closely with mining companies, OEMs, mine designers, and EPC/EPCM professionals to co-create tailored solutions. Meaningful conversations with customers help identify and meet their unique demands.

As modern mining operations become increasingly energy-intensive, the design of mines plays a crucial role in ensuring access to a reliable, 24/7 supply of renewable electricity, whether sourced directly from the grid or generated on-site. Advanced, bespoke monitoring and control solutions for both underground and open-pit operations ensure seamless power integration with energy management and storage systems.

ABB’s commitment to lifecycle services ensures that mining equipment remains available and efficient from installation through to decommissioning, maximising uptime and value. Another crucial aspect of ABB’s mining solutions is the application of intelligent control systems to critical infrastructure, without compromising safety. This is where ABB’s Ability™ System 800xA distributed control system comes into play, providing a fully integrated platform for mines to manage their operations more effectively.

A key example of this smart approach is ABB’s Ventilation on Demand (VoD) technology, which optimizes ventilation systems in large underground mines. Air circulation in these mines accounts for around 50% of their total energy consumption. By integrating ABB's VoD technology, mines can improve air quality while cutting energy costs by up to 50%.

Using smart tracking-and-tagging systems, combined with environmental and flow sensors, ABB’s VoD solution, known as ABB Ability Ventilation Optimiser, dynamically adjusts ventilation based on real-time data. By automating airflow management, the system not only ensures the right amount of air is supplied to the necessary areas but also reduces energy consumption by 40% to 50% a year, translating into savings of $2 million to $3 million for some operations. Van Zyl highlights a case where a mine saw a 54% reduction in ventilation energy use after adopting ABB's VoD solution in 2015, demonstrating the significant, immediate return on investment.

Whether for Greenfield or Brownfield projects, integration is the catalyst for optimisation. One powerful example is the use of motor controllers and drives to understand each device’s energy footprint. By linking this data to process performance, mines can detect performance and energy efficiency drifts from benchmark levels. Armed with this information, technical teams can make informed decisions to restore equipment to optimal conditions.

By integrating data from ABB Ability Asset Performance Management, mines can also turn predictive maintenance from a concept into a tangible reality, improving uptime and reducing unplanned downtime. ABB’s motto, ‘Great Minds, Great Mines’, reflects its commitment to partnering with mining companies to lay the groundwork for an industry that meets society’s economic and environmental needs. By pushing for innovation and adopting all-electric, fully automated mining systems, the industry can achieve real progress toward a sustainable and prosperous future.

As mining companies embrace the technologies and solutions that ABB offers, they are better positioned to succeed in a rapidly evolving world where efficiency, sustainability, and responsibility are not just goals – they are imperatives.