LEADING THE WAY WITH
DISRUPTIVE MINING PROJ ECT PARTNERS:
INSIDE
GOLDCORP’S MINE OF THE FUTURE Written by Laura Mullan Produced by Richard Deane
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INNOVATING AT EVERY STAGE OF THE MINE LIFECYCLE, GOLDCORP’S PEÑASQUITO MINE HAS GROWN TO BECOME A SHINING EXAMPLE FOR THE MINING INDUSTRY, SHOWING WHAT AN EFFICIENT, SUSTAINABLE, AND DIGITALLYENABLED MINE SHOULD LOOK LIKE
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Historically, mining remains one of the last industries to be disrupted by technology,” observes Tim Kahl, General Manager of Operations at Goldcorp. “It’s ironic, because mining provides the raw materials for modern economies to work, but we’ve been slow to apply some of the technologies we’ve had a hand in creating. “Over the past few years, there’s
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been a fundamental shift. At Goldcorp, we want to promote disruption in the mining sector and we’re focusing on digitisation. We’re trying to change the image of mining and to make use of what the rest of the industrial world is doing digitally. I think in this way, Goldcorp is really leading the pack.” With every industrial revolution, businesses have evolved to create something unlike anything
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that has come before. Traditionally, the mining industry has been sluggish in its uptake of new technologies – but not at Goldcorp. Keen to disrupt the mining sector, the Canadian mining giant is zeroing in on emerging technological trends including automation, data analytics and even drone technology to redefine the way it does business. In doing so, Goldcorp is ushering
in a new era of digital transformation and operational excellence.
A MASSIVE OPERATION In the state of Zacatecas in Mexico, Goldcorp’s flagship mine is a mammoth operation to behold. Extraordinary in both its scale and production, the Peñasquito mine stands as the fifth largest silver mine in the
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world and the second largest in Mexico. “Peñasquito is by far the biggest open pit in Goldcorp’s portfolio,” Kahl says. “It accounts for 30-40% of all of Goldcorp’s production in terms of total metal output and it provides about 33% of the company’s total revenue. “We also have a lot of personnel and contractors on site,” he adds. “Therefore, we’re not just seeing how digitisation can increase our productivity, we’re also using technology to enhance safety and the more human elements of mining.” Across the mining sector, fluctuating metal prices can wreak havoc on a company’s bottom line; as a polymetallic mine, Peñasquito circumvents this issue. Producing gold, silver, lead and zinc, Goldcorp can adapt its strategy and focus on the most in-demand metal on the market.
A MULTI-METAL STRATEGY This also involves adapting its strategy and Kahl says this is where digitisation can be critical. “Depending on the market price for metals, we can either be focused on gold or zinc but this involves different strategies,” Kahl explains. “Digitisation can really help us determine what metal we should focus on and what operating model we need use. There are so many different technologies we can use – devices, apps, cloud technologies, next-generation analytics, robotics, smart sensors, virtual reality and artificial
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TIM KAHL General Manager of Operations at Goldcorp Tim Kahl is an executive with 24 years of experience in multinational mining companies working throughout North and South America, the Caribbean, and Mexico focusing on operations that include gold, silver, lead, zinc, and copper processing technologies. Operational experience includes open pit mining, flotation, heap leaching, crushing, sizers, wet and dry grinding, CIL/ Tails/Strip/Refining, refractory ore processing (whole ore autoclaving, roasting and their respective off-gas handling systems), and bioreactors. Kahl possesses a unique combination of experience including operations and maintenance, engineering, commissioning and start-up of complex plants through to full production, and multicapital project management. His expertise includes mine and plant operation and maintenance strategies, and also representing the owner’s team during the design, construction, and commissioning phases to deliver a functional operating plant that is also maintenance friendly. Key accomplishments include a strong record of delivering process plants within tight schedules and budgets for on-time production (important for maintaining shareholders’ trust and support), rapid plant rampup to name plate capacity, O&M optimization, cost reductions, and vastly improved safety performance.
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Chemours Mining Solutions Innovation and reliability for the mining industry.
Š 2018 The Chemours Company FC, LLC. Chemours™ y el Logo de Chemours son marcas de The Chemours Company.
Providing Technology, Innovation and Safety to the Mining Industry. Chemours Mining Solutions is committed to safe and reliable supply of sodium cyanide and enabling the continuity and success of our clients’ operations.
In our Mining Solutions division, we are global leaders in the production of solid sodium cyanide and the market leader in its distribution in Mexico. By partnering with us, you’ll benefit from a 60-year legacy of reliable supply, innovative packaging solutions, and industry-leading safety practices that continually add value to our customers. We develop lasting partnerships with our customers and strive for an unparalleled level of interaction so we can better understand their needs. We also work with them to establish the best safety standards and procedures for product transportation, facilities to unload the product and training of personnel. A standout example of this partnership can be seen at Minera Peñasquito, Goldcorp’s largest producing gold mine, proudly located in the state of Zacatecas, Mexico. Chemours and Goldcorp share a mutual commitment to safety and care for the environment. Our history with Peñasquito began in 2008, when we supported them with the design and commissioning of their cyanide circuit. In the same way, we verified that their operations were ready to work safely. Since then, we’ve earned and enjoyed ten years of safe uninterrupted supply to the mine. Likewise, we’ve supported Peñasquito by helping them obtain and sustain certification by the International Cyanide Code (ICMI) - of which we are founding partners - and in providing the required training to their technical and operational staff for the safe handling and management of sodium cyanide.
We have the capacity, experience and dedication you’re looking for in a service provider. We are committed with the communities where we operate. Our leading edge technology, our safe delivery systems, and our unique support in the industry have one objective in mind: Your SuCCeSS! We are committed to the safe and responsible production, distribution, and handling of sodium cyanide. Our safety practices comply the guidelines established by the ICMI. We are currently working to improve the packaging and management of our product to offer a better experience; we are achieving it by using innovative packaging, preselected routes, and certified personnel on site.
The Chemours Company is a global leader in Titanium Technologies, Fluoroproducts and Chemical Solutions, as well as in the safe and responsible management of chemical products. We are present in more than 130 countries; we serve more than 4,000 clients in regions like North America, Asia Pacific, europe and Latin America. We have approximately 7,000 employees and 35 production facilities around the world, which operate under the strictest local and international safety and environmental standards.
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intelligence, for example. “These are quickly influencing and challenging our conventional business model. Therefore, we have to be adaptive and really understand how we can transform our business model going forward. “While digitisation gets the right data to the right people to make decisions more quickly, we haven’t limited innovation simply to digitisation. Goldcorp’s ambitious Towards Zero Water strategy is one example. Through both continuous improvements on our recycling rates and breakthrough innovation,
the target is to reduce freshwater consumption to zero. We’re fundamentally re-thinking every aspect of our business to be safer, more productive and more responsible.” The team at Goldcorp have ambitious plans for the future. Last year, it launched an impressive plan to increase its production by 20%, lower all-in sustaining costs by 20%, and grow its reserves by 20%, all by 2021. Undoubtedly this goal wouldn’t be possible without the concerted efforts of its digital strategy. “I truly feel that the next wave of productivity gains are going to
“ Digitisation can really help us determine what metal we should focus on and what operating model we need to use” TIM KAHL General Manager of Operations at Goldcorp
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be primarily driven by technology and digitisation,” Kahl notes. “It’s even more important to recognise this if you’re a multi-national company like Goldcorp.”
AN INTEGRAL MANAGEMENT OPERATING SYSTEM Instilling a culture of continuous improvement is something which Kahl is fiercely passionate about. That’s why he says the company’s management operating system (MOS) is the cornerstone of its successes. “I’ve worked on many international mines from Argentina, Chile and Peru, to the Dominican Republic,” recalls
Kahl. “What’s a common thing that’s missing at a lot of the operations? A management operating system. “It’s kind of a playbook: it’s a guide which shows our standards, procedures, how we run and operate our business,” he explains. “We use our MOS to really stay on top of our operations and monitor how we’re doing. “Short interval control is critical,” he continues. “We really found that we can get large productivity gains by having short interval control installed. At all levels – from metallurgy to mine operations, processing, and even on the administration side – we’ve got
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VIDEO: the story of Peñasquito
MOS installed and I think it’s really the cornerstone of Peñasquito. It’s helped us turn a corner in terms of our productivity numbers, and continuous improvement projects.”
TAPPING INTO AUTOMATION From automated drills to self-driving trucks, automation is bringing the world of mining to new heights and it is an area where Goldcorp is seeing promising results. “We’re currently trialling
autonomous drilling and, although it’s still in its infancy, we’ve had great successes,” says Kahl proudly. “The productivity gain has been incredible. We’ve seen approximately a 25% improvement in our total productivity from the autonomous drills. Now we’re looking to convert and replace drills as we retire them with autonomous alternatives.” Often referred to as the ‘new oil,’ big data is also helping Goldcorp address the barrage of
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challenges that the mining industry faces today. To reap the benefits of data analytics, the Canadian firm has teamed up with leading data management companies to unlock the potential of the Mexico mine. “We need new technologies to provide analytics for real time decision making,” notes Kahl. “In the last couple of years, we have been working closely with companies like OSIsoft to integrate thousands of sensors, collect data from all areas of the mine, and together unlock the power of data analysis and process control. It’s about using this data to more accurately forecast our performance plan and to drive improvements through short interval control.” This is just the beginning, Goldcorp is also partnering with technology giant IBM to develop new ways to analyse geological data. “By utilising IBM’s Watson artificial intelligence and machine learning
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1994 The year that GOLDCORP Inc. was founded
QUALITY AND EXPERIENCE ADDED VALUE
We are a service company focusing on the large diameter and depth drilling wells for the mining industry, providing solutions in areas such as; production, operation, maintenance, dewatering, community relations and development and monitoring wells.
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We are respectful and honest with customers, employees, suppliers, authorities, society and the environment.
LEADERSHIP
We direct, develop and organise our human capital to be at the forefront of the market
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We protect the welfare of the staff, safeguard the properties and assets of our company, as well as our clients.
COMMITMENT
We get involved with our clients and collaborators, looking for the maximum satisfaction of their needs.
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We integrate our human capital in harmony to generate development and achieve results
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PA S S I O N
We thoroughly enjoy what we do to provide a vital service to our customers
www.permex.com.mx contacto@permex.com.mx
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“In the last couple of years, we have been working closely with companies like OSIsoft to integrate thousands of sensors, collect data from all areas of the mine, and together unlock the power of data analysis and process control� TIM KAHL General Manager of Operations at Goldcorp
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Los Expertos en Voladuras The Experts in Blasting Systems
Nuestro futuro depende del ĂŠxito continuo de nuestros clientes Our future depends on the continuous success of our clients
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VIDEO: Thermal equipment inspection via drone
system, we expect to improve our success and velocity in exploration.�
THE HIGHEST SAFETY STANDARDS Health and safety is a huge talking point in the mining sector and it is here where the true value of data and technology really shines. At its pioneering PeĂąasquito mine, Kahl explains how Goldcorp is employing digital monitoring systems and Light Detection and Ranging
(LiDAR) to monitor any potential harmful events or conditions. Zooming across the skies of its deep open pit, Goldcorp has also tapped into the use of drone technology to monitor its pits, its roads, and more. On top of this, his team is also exploring collision avoidance technology to help reduce equipment damage and the number of metal on metal contacts. Working alongside KPMG and Finger Food, Goldcorp is also
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exploring using augmented and mixed reality technologies to provide operators real time data right at the machine interface to improve operator efficiency and safety. “We’re making great strides in our technology but it’s not just about productivity, it’s also about protecting our people,” Kahl says. Yet, whilst Kahl highlights the remarkable digital transformation Goldcorp has undertaken, he doesn’t underestimate the talent and expertise of his team who helped make this vision a reality.
INDUSTRY-LEADING EXPERTISE Offering a positive work culture means that the Canadian firm has been able to attract, and more importantly retain, some of the best talent in
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14,094 The number of staff working for GOLDCORP Inc. (2017)
Digitalization – Future of the mining industry Digitalization can help the minerals sector tackle major challenges like productivity improvement. To drive the progress of highly efficient and sustainable mines, Siemens offers proven digitalization solutions: an industry-specific process control system for comprehensive automation (MinAS), an engineering tool for effective plant management (Comos), and a platform for aggregating, relating, and presenting operational and business data for the big picture (XHQ). It’s time for a higher degree of digitalization to gain a true competitive edge.
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MINING
the industry and, by hiring locally and supporting local business wherever possible, 73% of today’s workforce at Peñasquito is from the local Zacatecas region. “Typically, a mine isn’t going to be near a large urban area and so it can be a challenge to attract good, young expertise,” notes Kahl candidly. “It is difficult, but we have been able to attract some very talented people. Ultimately, what it comes down to is that there’s got to be a good challenge for that individual, we have to be flexible with their work schedule, and we have to make sure it’s right for them.” With such a root-and-branch transformation of its digital offering,
Goldcorp has completely redefined its daily operations. Yet with such vast changes, Kahl says there has definitely been a cultural shift within the company to help promote this use of innovative technology. “We’re also trying to make our workforce more digitally-enabled,” adds Kahl. “In a portion of the pit, we’ve already implemented an electronic operator scorecard and in conjunction with this, we are aiming to more effectively utilise our work order management system. “I think in general it’s going to help us reduce our costs,” he continues. “Some of the issues we face on a dayto-day basis are fairly complex, and by utilising this we can really drive our value
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“ Some of the issues we face on a day-to-day basis are fairly complex, and by utilising this we can really drive our value chains. In the end, I think it’s going to improve our safety, our costs, and improve our productivity” TIM KAHL General Manager of Operations at Goldcorp
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chains. In the end, I think it’s going to improve our safety, our costs, and improve our productivity.” Keen to promote collaboration within the sector, Goldcorp has also formed strong relationships with industry-leading companies including Gruas del Norte, Alchisa (Aceites Lubricantes de Chihuahua S.A), Permex, Komatsu, FLSmidth, Fluor, and Orica. In doing so, the Canadian firm has gained the expertise and knowledge it needs to raise the bar in the mining sector.
OVERCOMING HURDLES AND ACHIEVING SUSTAINABLE GROWTH Goldcorp has completely reinvigorated its digital strategy with diligence and ingenuity. Yet this hasn’t
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$
3.42BN
Revenue for GOLDCORP Inc. (2017)
SERVICE 24 HOURS A DAY, 365 DAYS A YEAR. We provide integral solutions for the movement and transportation of all kinds of vehicles, structures and machinery, through personalized attention, reliable and above all with high quality, according to the needs of each of our customers.
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come without its challenges. “I think having an effective, functional network is always tough,” reflects Kahl. “As you get more connectivity points and your usage goes up, it becomes more and more critical. As you go down in the pit it gets harder to get signal and that’s been one of the biggest challenges we have faced – getting full coverage throughout our pit operation. We’re working diligently to tackle this and we have implemented a few architectural changes to strengthen our connection backbone.” Technological innovation
has created riptides in almost every industry and it’s been no different in the world of mining. Peñasquito is an exemplary mine which clearly demonstrates the true value digitisation can provide in terms of a mine’s operational excellence, safety, and financial standing. Yet, for Kahl, it seems this focus on digitisation and innovation isn’t simply about collecting new software and gadgets, it’s about seeing continuous improvement and creating meaningful change in the sector. “When I started out my career in
“ In 2018 we’ve committed to gain $25mn in additional revenues through cost savings, production and productivity factors at Peñasquito. I really think continuous improvement and digitisation are what we need to achieve this” TIM KAHL General Manager of Operations at Goldcorp 30
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the mining industry, the environment promoted continuous improvement and fostered new ideas at all levels of the organisation,” he says. “When I was a young metallurgical engineer I used to think that continuous improvement was just additional documentation, but I quickly realised that it’s what transforms your business, and what makes it profitable. It’s a part of our operations, our atmosphere and our culture and it makes work so much easier. “I think it’s incredibly important, and everywhere I go I try to instil that continuous improvement culture
because it’s really been instilled in me since I started in this industry. In the late 1990s or early 2000s the gold market value fell to levels of around $250 per ounce. I think it was continuous improvement which distinguished which companies remained operable or not. “In 2018 we’ve committed to gain $25mn in additional revenues through cost savings, production and productivity factors at Peñasquito. I really think continuous improvement and digitisation are what we need to achieve this.”
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Goldcorp Inc. Park Place, Suite 3400-666 Burrard Street, Vancouver, B.C. Canada V6C 2X8 T (604) 696-3000 E info@goldcorp.com WEB www.goldcorp.com