What is Zero Entry Mining?

Jeff Sterling, Managing Director, Universal Field Robots

"What is zero entry mining?” was the question asked at a recent Global Mining Guidelines Group (GMG) event. The variety of discussions highlighted that the definition is still being written, and there are many questions yet to be answered.

Why pursue zero entry mining anyway?

This article may answer some of the questions that arise.

• Is it just about enhancing safety, reducing costs, and addressing the shortage of people?

• Are mine automation and robotics already active in Australia? What can they deliver now?

• How long before they are ubiquitous?

• And what are the risks for the mining executives eager to commit to the journey?

Defining zero entry mining

The term 'zero entry mining’ makes us imagine no people in hazardous work areas – something like the Mars rovers. Earthside, a more workable aim is reduced exposure to hazards, and workers outside of an Autonomous Operations Zone (AOZ). Fun fact: Mars is the only planet completely inhabited by robots.

Efficiency evangelists tell a zero entry story of smaller machines, like termites, only taking the good stuff. Examples include small haul trucks on narrow roads, 24/7 mining with brief pit stops, work-around blasting, and eliminating ground support.

Zero entry mining is likely a combination of these ideas, with an emerging and evolving definition.

Zero entry mining points the way to different ways of working. Success in this space will save lives, reduce costs, and allow mining executives to sleep better at night. So, what are we waiting for?

Is there any urgency to go to zero entry?

Queensland tragically records an average of 2.4 deaths and around 80 to 100 serious accidents annually. Statistics are reported as a cycle of increases followed by decreases without a downward trend.

Mining uses procedures and training, which tend to make humans operate like robots. But human factors science reveals that repetitive tasks dull attention and create vulnerability for unexpected and unlikely adverse events. People are creative, distracted and get tired, unlike robots.

Zero entry with automation has now operated in haulage for some years and has delivered safe operations by lowering exposure to hazards. Mistakes with light vehicles around autonomous trucks have been reported, however, collision avoidance has stopped trucks autonomously.

The haulage example demonstrates that disruptive change delivered with zero entry is preventing people from being harmed.

What about costs?

Full entry mining incurs ‘lost time’ due to implementing procedures, training, isolation, blast clearance, pre-start checks and shift changes. Cost of mining also incorporates expensive protective systems such as PPE, ground support, wide haul roads, haul road berms, tag boards, wheel chocks, evacuation ladderways, FOPS, ROPS, radios, onboard reporting systems, CAS, and reversing alarms, to name just a few.

Tier 1 mining users report automation savings due to increased utilisation, lower maintenance, and less damage. Back-of-the-envelope calculations suggest significant savings at around 50% are possible.

What about the people shortage?

Labour shortages are continuing and could be the start of an ever-tightening labour market. Shortages have been met with 457 visas, backpackers, and FIFO from ever-larger catchments.

The COVID-19 pandemic further exacerbated these problems, with South American mines reporting shutdowns, leaving only mines that use automation able to operate.

Introducing zero entry requires new skills and roles, but jobs have proven to be sought after, as they provide high-quality work and future-proofed employment. City-based operating centres open opportunities for diversity and can also increase the employee value proposition.

Are automation and robotics a serious option to do the dirty work?

Zero entry with automation is becoming easier. Equipment has evolved and is now digitised. Levers are replaced with joysticks to transmit digital messages to ECUs (computers). Integration of vehicles with digital control is often almost plug-in, which can reduce time, cost and risk.

Equipment driving without drivers uses clever software to create control, similar to when we shut the fridge door and the light obediently goes out. And $100 billion of spending on self-driving cars has made the impossible possible and that technology is now diffusing into other sectors.

WiFi and connectivity are now part of our lived experience. Mines are being fitted out to provide various services allowing remote supervision of automation from central or city control rooms.

In blasting, new wireless detonators reduce barriers for automated placement of initiation systems. Automation of explosives loading and stemming will facilitate variable density explosives dialled to deliver fragmentation. All these new technologies will aid and drive the uptake of zero entry.

Where are we at with zero entry?

The world's autonomous fleet comprises around 1,000 machines: 200 tonne-plus haul trucks, 200 large blast hole drills and hundreds of loaders underground. Data is captured with drones capturing survey, and automated blast-hole logging collecting data from below the surface.

In underground mines, development is progressing with the automation of haulage, drilling, shotcrete, hole cleaning, survey and charge-up, all set to roll out over the next few years.

Prototypes of cab-less electric mining machines in smaller sizes will offer potential lower cost options and open possible new mining methods to enhance sustainability.

What are the risks for the mining executives eager to commit to the journey?

Zero entry has been dominated by the largest mines of the largest producers and delivered by the largest equipment manufacturers. These mining majors with the deepest pockets have been able to force successful autonomy outcomes, but often with false starts, missteps and scar tissue formed along the way.

Execution risks

Execution risks are real and need to be managed. Smaller-scale starter projects can raise skills with site teams and highlight gaps. Staged experiments with gates and defined graduation success at each gate will limit the risk of running off the rails.

In the white space between the big machine activities, smaller tasks consume labour and create exposure to hazards. These smaller tasks can present lower execution risk, high-value creation entry points, and an opportunity to demonstrate early success and build confidence.

Culture and people risks

The lack of a supportive culture has proven an issue in introducing zero entry. Change creates concern and can be countered by communicating the strategy, making the case for why, and taking stakeholders on the journey. Finding and empowering enthusiastic champions can make a major impact on execution success.

New skills are necessary and there is undeniably a labour shortage. Selecting good partners and training people within existing teams can be used to get projects going and facilitate skills transfer to the wider organisation.

For mining executives, automation and zero entry are a frontier with risks, but equally, they represent an opportunity for significant rewards. Identifying the future state benefits and building a solid business case will certainly engender support.

At the end of the day, operators can fall asleep at the wheel, and automated haul trucks can’t. Zero entry mining points the way to different ways of working. Success in this space will save lives, reduce costs, and allow mining executives to sleep better at night. So, what are we waiting for?