Mining Digitalisation: Turning challenges into opportunities

As 2026 approaches, the mining industry stands at the threshold of a transformative era driven by digitalisation. The sector faces increasing environmental pressures, societal demands, and economic challenges, necessitating a shift towards more sustainable and efficient practices.

Digitalisation is emerging as a fundamental strategy for future-proofing the industry. Technologies that enhance operational efficiency, improve safety standards and increase productivity are becoming widespread, with maximum growth anticipated between 2021 and 2026. This trend underlines the essential role of digitalisation in driving innovation and sustainable growth in the mining sector.

The resilience and inventiveness that have long defined the mining industry are now being channelled towards embracing this digital revolution. Technologies that were once peripheral are now central to addressing the industry's most pressing challenges, from improving safety to complying with stringent environmental and social governance (ESG) standards. Additionally, new challenges, such as cybersecurity, are gaining prominence, while traditional concerns like ESG and the license to operate LTO) demand innovative approaches.

Digital transformation in mining

The mining industry is currently undergoing a significant shift towards digitalisation. Several technologies are helping to reshape mining operations:

Autonomous Vehicles: These vehicles, capable of functioning without human intervention, enhance operational efficiency by performing tasks such as drilling and transportation more safely and consistently.

Remote Operating Centers (ROC): These centres allow for centralised control and oversight of mining operations, enabling experts to monitor and optimise processes remotely.

Advanced Data Analytics: The use of data analytics helps to optimise production, reduce inefficiencies, and support decision-making. Data-driven insights enable mining operations to align more closely with production goals, safety standards, and ESG targets.

One of the key examples of integrated digital operational control is illustrated in Figure 1.

As mining companies embrace digital transformation, innovations like autonomous vehicles, remote operating centres, and data analytics become pivotal for growth and sustainability. However, the shift towards digitalisation also requires overcoming challenges related to infrastructure compatibility, cybersecurity, and workforce upskilling. These challenges must be addressed through collaboration and continuous innovation to drive long-term improvements across the sector. The automation pyramid for mining and minerals processing is depicted in Figure 2.

Cyber-Physical Systems and Industry 4.0

As technology continues to evolve, new systems such as Cyber-Physical Systems (CPS) are being implemented within the mining industry. These systems allow for decentralised communications and autonomous decision-making. CPS architecture adapts to its surroundings and facilitates peer-to-peer communication, making the system more flexible and capable of responding to changing conditions.

The importance of Cyber-Physical Systems in Industry 4.0 implementation is evident, as it aims to flatten traditional automation structures, reducing the steps between decision-making and control. Figure 3 provides a visual representation of a Cyber-Physical System.

Enhancing mining safety through digital transformation

Safety remains a top priority in the inherently hazardous mining sector. Digital transformation has introduced new safety measures that redefine traditional protocols and establish higher safety standards. Some of the digital technologies shaping safety include:

• Fatigue Management Systems: These systems use wearables and in-vehicle technology to monitor worker fatigue, issuing alerts when rest is needed to prevent accidents.
• Wearable RFID Locators: These devices track workers in real-time, particularly in emergencies like cave-ins, enabling quick response and improving rescue operations.
• Proximity Sensors: These sensors prevent accidents by detecting personnel and machinery proximity, and issuing alerts when there is a risk of collision.

Short Interval Control (SIC) in mining operations

Short Interval Control (SIC) is a method of dividing work into short, manageable intervals, enabling real-time monitoring and adjustment of operations. SIC facilitates immediate responses to operational changes, aligning with production goals and safety standards. The core components of SIC include:

• Real-Time Data Utilisation: Advanced sensors and IoT technology capture operational data, enabling quick decision-making and adjustments.
• Productivity and Efficiency Gains: SIC can improve productivity by 10-20% through the real-time identification of inefficiencies and rapid corrective actions.

However, implementing SIC requires robust connectivity and data management systems to ensure seamless operation. Figure 4 presents the building blocks of short-interval control.

SIC implementation also involves cultural shifts within mining companies, requiring workers and supervisors to adopt a data-driven mindset and continuously strive for improvement. Figure 5 illustrates the DIKW (Data, Information, Knowledge, Wisdom) Pyramid—a model that highlights the transformation of data into actionable wisdom.

Strategic asset planning and integration

Digitalisation also revolutionises strategic asset planning and integration within the mining industry. Digital tools enable data-driven decision-making, dynamic planning, and real-time updates, enhancing alignment between strategic goals and frontline operations. These tools foster a more integrated view of operations, breaking down traditional silos and supporting coordinated actions across the mining ecosystem.

AFRY Smart Platform: Supporting digital transformation

AFRY has developed the AFRY Smart Platform, a modern digital platform based on open-source and low-code technologies. The platform allows clients to easily expand their Industry 4.0 horizons, providing an affordable and user-friendly solution free from vendor lock-ins. This platform supports various industry-specific applications, such as centralised production control through ROCs, and fosters a culture of digital innovation. By integrating tools like the AFRY Smart Platform, mining companies can better adapt to the changing digital landscape, ensuring sustained growth and operational success.

Pioneering innovation in mining

As the mining industry advances into its digital future, it encounters formidable challenges but also unparalleled opportunities for transformation and growth. Embracing digitalisation, mining companies stand on the cusp of revolutionising their operations, making them safer, more efficient, and more sustainable. This pivotal shift, while demanding adaptation across technological, cultural, and operational facets, promises to position the industry at the forefront of innovation. By navigating the digital landscape with strategic foresight and a commitment to continuous improvement, mining enterprises can secure their success and resilience in the years ahead, charting a course toward a future where technology and tradition converge to redefine excellence in mining.