Mining Magazine – October 2023 by Mining Global

October 2023 | miningdigital.com

EXYN TECHNOLOGIES

MAPPING THE MINESCAPE Turner Mining Group Safety and innovation core values

International Copper Association Australia Net zero copper mining

Rare-earth metals Looming crisis raising sustainability concerns

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FOREWORD

Technologies enhancing mining operations By incorporating automation and autonomous vehicles into mining processes, human efforts can be extended more effectively, reducing variability and minimising human error

“Digital technology has played a crucial role in reshaping the mining landscape in the past decade or so”

MINING MAGAZINE IS PUBLISHED BY

Technologies like remote monitoring, mobile mapping, and high-precision data collection have already significantly enhanced the efficiency and productivity of mining operations. This month, we look at Exyn Technologies' autonomous aerial robot systems for complex, GPS-denied environments and explore how the company is delivering exciting innovations for the mining industry. The benefits of these advanced solutions from companies like Exyn can’t be overstated. With safety becoming the most important core value for all mining companies, digital technologies can enhance worker safety by reducing the need for human operators to enter hazardous environments. Drones can be used for inspections in dangerous areas, and remote-controlled machinery can perform tasks that previously put employees at risk. “Digital technology has played a crucial role in reshaping the mining landscape in the past decade or so,” Ben Williams, COO of Exyn Technologies tells us. With this in mind, these advanced technologies promise to offer tremendous opportunities going forward. scott.birch@bizclikmedia.com

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CONTENTS

10 30 10 AI IN MINING Exyn: mapping the minescape

18 TURNER MINING

North America’s trusted mine services contractor

30 NET ZERO

Next step to net zero copper mining

40 TECHNOLOGY The looming crisis in rare-earth metals 8

October 2023

OCTOBER 2023

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AI IN MINING

EXYN: MAPPING THE MINESCAPE We look at Exyn Technologies’ autonomous aerial robot systems for complex, GPS-denied environments and some exciting innovations for the mining industry WRITTEN BY: JOHN O’HANLON

xyn Technologies specialises in creating autonomous systems that navigate and map challenging, GPS-denied environments. Its systems are used in industries as varied as mining, logistics, geospatial data, infrastructure, construction, and government. With ExynAI, it meets the growing demand for autonomous mapping across a wide range of applications. Tech transforming mineral exploration and extraction For instance, the establishment of comprehensive digital communications underground has improved information flow both below and above ground. “Digital technology has played a crucial role in reshaping the mining landscape in the past decade or so,” affirms Ben Williams, COO of Exyn Technologies. “Looking ahead, autonomy, big data, and analytics tools still offer tremendous opportunities to transform mining operations in terms of application and impact.” Another perspective on these transformations revolves around efficiency and productivity. Information technology, in its essence, serves as a tool to streamline the flow of information in all its diverse forms. Technologies like remote monitoring, mobile mapping, and high-precision data collection have already significantly enhanced the efficiency and productivity of mining operations. Moreover, by incorporating automation and autonomous vehicles into the actual mining processes, human efforts can be extended more effectively, reducing variability and minimising human error. These advancements facilitate uninterrupted, round-the-clock operations while minimising downtime. The mining industry generates vast amounts of data miningdigital.com

AI IN MINING

Our autonomous, industrial-grade robots can easily navigate complex environments, using onboard sensors and AI to accomplish the mission without a pilot, GPS, or a prior map

from sensors, IoT devices, mobile mapping, and autonomous systems. Leveraging advanced analytics and machine learning algorithms, this data can be processed to optimise mining procedures, anticipate equipment maintenance requirements, and enhance the quality and speed of decision-making. Giving mines the Exyn ‘edge’ Since its inception in 2014 Exyn has continuously disrupted the mining technology landscape. In 2020 it unveiled the ExynAero drone, which launches at the press of a button, and navigates pilotfree through the entire stope in a single flight rapidly producing precise 3D maps, sensor data, and georeferenced models. Mining companies have recognised that

these new ways of doing things are far more accurate, efficient, and safer than traditional manual methods. The growth in demand for autonomous mapping technology in the mining sector is driven by safety concerns, operational efficiency, and compliance requirements. Digital tools, like 3D modelling and geospatial analysis, are helping mining companies identify new deposits, plan extraction strategies, and optimise the use of resources. This year it announced the ExynAero EA6 drone airframe, US-built to meet commercial customer demands. Beyond sourcing a new airframe manufacturer, Exyn was searching for a partner with a product that would be capable of evolving with them. By adopting the customised Osprey drone Exyn gains greater flexibility on future miningdigital.com

The Exyn story • 2014 - Founded by Nader Elm and Dr. Vijay Kumar as a spin out of The University of Pennsylvania’s General Robotics, Automation, Sensing & Perception (GRASP) Lab • 2015 - Exyn opens its first office at Pennovation. Inaugural flights of ExynAI begin • 2016 - FirstAutonomous GPS-denied flights with ExynAI. Expand offices to Venture forth (NE Philadelphia) • 2017 - Awarded Startup of the Year from Penn’s Center for Innovation. Further office expansion to Washington Avenue in Philadelphia. Invited to fly the first ever aircraft inside the Smithsonian National Air & Space Museum • 2018 - Exyn begins underground testing of ExynAI including demonstrations for SEPTA and Dundee Precious Metals. Joined Team PLUTO to compete in the DARPA SubT Challenge. • 2019 - Raised $16+ million in Series A round, filed first round of patents with USPTO, and delivered the first set of Exyn A3R’s to Dundee Precious Metals • 2020 - Exyn unveils its product line for the mining industry, the ExynAero and ExynPak • 2021 - Exyn opens its first Canadian office at the NORCAT Underground Centre • 2022 - Exyn ranks #177 on the Inc. 5000, and unveils AL4 autonomous exploration on a Boston Dynamics Spot with Trimble x7 payload • 2023 - Enters partnership with Easy Aerial and announces the ExynAero EA6 platform

October 2023

adaptations based on customer feedback, and to quickly iterate on key software or hardware to ensure enhanced reliability and safe flight. Exyn also benefits from the option to expand its offerings to include EA’s dronein-a-box solution, automated charging, and remote operations to further automate their autonomous robot. Partner Easy Aerial and Exyn, both agile and dynamic startups, were able to quickly and nimbly adjust to customer feature requests, supply chain constraints, new sensors, and specialised configurations. In addition, Easy Aerial and Exyn are ISO-9001 certified and

AI IN MINING

“Big data and analytics tools still offer tremendous opportunities to transform mining operations” BEN WILLIAMS

COO, EXYN

Exyn’s autonomous robots can intelligently navigate feature-rich indoor and outdoor environments, scanning buildings for situational awareness without requiring the cognitive load of a pilot

Easy Aerial is AS9100 certified, which will help facilitate quality production of the ExynAero EA6. The Osprey platform is beneficial to Exyn in business verticals like mining and construction, but as a Blue sUAS certified platform by the Defense Innovation Unit (DIU), it is especially advantageous for Exyn’s work in the government sector. The Osprey is a durable carbon composite hexarotor airframe that provides motor redundancy in case of failure. The platform offers longer airborne endurance, while maintaining a slightly smaller form factor than the previous M210 and accommodates increased thrust capabilities.

Exyn’s products gather data in a complete and efficient manner to create a digital twin of the mine. “We gather the 3D point clouds and use them to create ‘meshes’, which are models of the stopes,” explains VP Commercial Sales Raffi Jabrayan. “Given how complete our data is, the technical services team is able to make decisions about the quality and volume of the blasting. Furthermore, given the speed with which we operate, this information is available to them immediately after the scan.” Exyn’s technology and products are an extension of the miners, Raffi points out. miningdigital.com

AI IN MINING

Digital: A New Era in Mine Safety, Panel Discussion WATCH NOW

“They are not intended to replace the employee, but to give them a tool that allows them to enhance their ability to do their jobs more efficiently, accurately, and safely! It also allows them to learn new skills and keep abreast of the latest technology. Exyn products are in line with existing industry methods, however we are far more advanced with our autonomy, mapping capabilities, and efficiency. This provides far greater ROI for mining companies that are working with us. Recently, USC Consulting did a white paper at one of our customers’ sites in Alaska that can speak to this.” Exyn has many developments planned, including expanded capabilities to support outdoor flights and remote actuation, allowing mines to use a single product for many different applications. This will change the way mapping and scheduling is done in mines by reducing the down time between blasting and mapping and reducing the need for personnel at the face. 16

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“We feel that our product is useful for small and large-scale mining operations,” concludes Raffi Jabrayan. “A single mine with an ExynAero or ExynPak will see immediate results. Larger operations will require larger fleets, but their ROI will be to scale. We have customers with a single site, others with eight sites. We provide the same level of service and support to all of them, as we know our products have become an integral part of their operations, and will help cut down time.” Safety and sustainability – in and beyond the mine Digital technologies enhance worker safety by reducing the need for human operators to enter hazardous environments. Drones can be used for inspections in dangerous areas, and remote-controlled machinery can perform tasks that previously put employees at risk. In fact, safety has become the most important core value for all mining

companies, and Exyn Technologies is proud to play such a major role in that. In traditional stope surveying, the miners would have to get dangerously close to the “face” to do their job. They could be working very close to falling rock, or dangerously near a large stope opening. Exyn changed all of that with its technology. Now, a surveyor can safely operate under fully supported ground more than 30 metres away, and do their job with more accuracy. Furthermore, given the speed with which Exyn products work, the same task can be completed in a fraction of the time which a surveyor used to need to spend underground. For the mining company, automation and remote monitoring can have a dramatic effect on the number of lost time accidents (LTAs) that are key to assessing the company’s HSE performance. They are also essential in assessing the mine’s social, environmental and sustainability performance. Tracking these impacts and designing appropriate

mitigation has become far easier as Exyn’s digital solutions enable better monitoring, improved waste management, and more efficient resource utilisation. Ben Williams sums up his complex organisation: “The benefits of using autonomous systems in demanding industries like mining cannot be overstated. Exyn is proud to be at this intersection – helping to keep miners safe, making mines more efficient, and providing rich, real-time datasets that allow operators to make decisions quickly. Technology has revolutionised the mining industry by improving safety, efficiency, and environmental responsibility while reducing costs. These advancements have enabled mining companies to operate more responsibly and profitably. That is the story so far. At Exyn, we are poised to continue to evolve our technology to help the mining industry stay at the forefront of innovation.”

Equipped with an ExynAero, survey teams can map multiple underground cavities in a single shift and produce georeferenced point clouds on-site for peak operational efficiency

miningdigital.com

TRU

October 2023

NORTH AMERICA’S USTED MINE SERVICES CONTRACTOR WRITTEN BY: TOM SWALLOW PRODUCED BY: BILLY EVANS

miningdigital.com

TURNER MINING

Safety and innovation at the core of Turner Mining Group and its Founder, Keaton Turner, delivers promise of strategic integration into client operations

or a mining company, Turner Mining Group is a fairly young business in the realm of digging and exploration. The demand on mining for natural resources ceases to shrink, giving new organisations a chance to bed in and enjoy returns from a number of evolving industries. With this in mind, there is something to be said for a business that, in this sector, is capable of becoming a strategic partner and providing long-term solutions to meet growing demand. In 2017, along came an organisation that commits to providing a trusted service and positive attitude towards the transformation of the mining industry, driving prosperity among site owners. Understanding the impacts of mining is one thing, but shaping them is another – Turner Mining Group is here to support partnering organisations to do just that. The company came from humble beginnings as a small startup mining subcontractor. It now employs more than 500 workers to deliver expertise for its US partners. From copper, gold and silver to cement, sand and gravel, Turner Mining is holistically capable of delivering the goods that its clients need through excavation and load carrying. Cue Keaton Turner, Founder and President of Turner Mining, the man behind the business and an experienced professional in excavation.

October 2023

Being the entrepreneurial man that he is, Turner combines his passion for an industry he was brought up in with recognition of the need for change as the playing field evolves. This means leveraging smarter solutions to get employees up to efficient speed in a safe way – safety and pace being key areas that allow mining organisations success in today’s landscape. Through Turning Mining Group, he took on the challenge to building a team of professionals that will not only leverage the expertise of a historically older workforce, but encourage excitement around mining by bringing technology into the fold. 22

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To fully understand the extent of which Turner Mining discusses its workforce, Turner himself cites a scenario where the leadership team comes together to focus its attention on leading, educating and empowering employees in the business. “I spent all day in a room with our leadership team, really experienced guys in their late 50s and 60s. We talked about our values, not about the numbers or production rates or equipment,” Turner says. “We talked about leadership because that is the hardest part of it. Getting older, more experienced guys to work well with young, passionate people. Transferring that

TURNER MINING

“ WE’VE HAD SOME CUSTOMERS TAKE BIG CHANCES ON US AS A YOUNG COMPANY” KEATON TURNER

PRESIDENT AND CEO, TURNER MINING GROUP

KEATON TURNER TITLE: PRESIDENT AND CEO INDUSTRY: MINING

knowledge to them in a way that the younger ones want to receive it. It’s reinforcing, not derogatory. It’s a real challenge.” This is one of the three core values of Turner Mining Group. Coming under the ‘heart for people’ statement, the business is also dedicated to technological innovation and safety as critical constructs for a socially responsible heavy-industry company. “If you’re not doing it, you’re not doing your job. I’m that style of guy,” says Turner. “The problem with that is you start to create a production-oriented culture. You forget about safety, you forget about

EXECUTIVE BIO

LOCATION: UNITED STATES Keaton Turner is the Founder and President of Turner Mining Group. An accomplished business leader with a broad understanding of the mining industry, Keaton has demonstrated exemplary leadership in various facets of business, encompassing new business acquisition, site operations, vendor strategy, and client relations. Before establishing Turner Mining Group in 2017, Keaton held pivotal roles within his family’s heavy/ civil excavation company, where he provided astute supervision for strategic direction, operations, and commercial development. His responsibilities extended to project design, estimation, operations management, and partner coordination. Keaton holds a BSc in Construction Management and Business Administration from Indiana State University.

miningdigital.com

TURNER MINING

excellence. It’s all just a to-do list. And the to-do list never goes away. It only gets longer. So, we sat with our team and really reflected on our values. “One of the lessons I’ve learned this year is if I’m not leading the organisation with values-based leadership, we’re never going to become the company that I think we can.” In order to really integrate staffing as a key component of business success, Turner Mining Group devised a separate organisation from its contracted roles to enhance its perspectives for hiring new employees. The company is focused on hiring and developing team players that are excited to get involved, but also meet the business’ new-found values.

October 2023

Turner Mining Group: • The company acts as a contracting partner in the mining industry. • When hired, it is responsible for bringing the necessary equipment and workforce to execute a project. • It bears the risks associated with production, equipment, and personnel. Turner Staffing Group: • The company has an effective brand and strategy that attracts a large number of potential employees to the mining industry. • Last year Turning Mining Group realised they had a pool of 3,000 potential employees (“sitting on the bench”) but couldn’t accommodate all of them in their own operations.

Keaton challenges this perception, suggesting the issue is not a shortage of workers, but rather the industry’s inability to capture the right attention. Turner Mining Group, however, does not face this issue due to its marketing and social media efforts. • Seeing the need in the industry and their excess potential workforce, they began offering staffing services. • Their staffing pool consists of a variety of skilled workers ranging from blue-collar roles like haul truck drivers and operators to white-collar roles like geologists and IT professionals. • Turner Staffing Group also offers direct placement services, helping other companies find specific roles they couldn’t fill themselves.

• Despite this vast pool, many companies in the US claim there is a labour shortage in the industry.

miningdigital.com

“ ONE OF MY FOUNDING PRINCIPLES WHEN WE STARTED, AND IT’S ACTUALLY ONE OF OUR CORE VALUES NOW, IS A HEART FOR PEOPLE” KEATON TURNER

PRESIDENT AND CEO, TURNER MINING GROUP

October 2023

Not only does the staffing business provide Turner Mining Group with a steady stream of new talent, but also helps other companies in the mining industry fill their vacancies – in a noble attempt to create jobs, meet demands and build alliances. The success of this recruitment drive has helped Turner Mining deliver personnel services to some of the biggest names in the US. As he understands the significance of its position and the scale of impact on its community, Turner is grateful for the growth that the business sees today. Operational safety: A necessity, not a trend With a strong social agenda, Turner is committed to not only growing the business,

TURNER MINING

but meeting its employees’ needs to ensure they are in good stead for the future. This is achieved primarily by the company’s efforts to keep its workers out of harm’s way, with safety a vital consideration for all members of staff. A company-wide strategic approach to safety is therefore required, as Turner himself explains. “Safety is one of our core values. To me, safety is a living, breathing culture. You’re either building a culture of safety or you’re killing a culture of safety,” says Turner. “We talk about it all the time. We just had another successful MSHA visit with zero citations and they visit every site twice a year. “I believe as a contractor we’ve got to become better than the mine owner or the

mine operator. If we’re not, they probably shouldn’t even hire us. So, we’re building a world-class safety programme.” This really echoes the firm’s duty to not only support its staff, but also bring this mindset to its customers’ sites. Understanding how to ensure its own safety criteria is met makes Turner Mining Group a suitable partner to bring into the fold and uphold on-site safety, or even help its partners to analyse and improve mining practices. From an operational standpoint, Turner is also aware that technology will have an increasing presence on site with communication being a crucial part of safety, but also the adoption of autonomy in the future. “I think semi-autonomous equipment is here. I think fully – autonomous equipment, at least in the huge mines, is there. But it’s going to be a while before it reaches scale at all mines,” says Turner. This is an area of development that will require expertise to deliver more autonomy, which is where the company relies on its partners, OEMs Caterpillar and Volvo, and dealers like Komatsu and Core Machinery, (formerly known as Road Machinery), to provide the equipment and technology capabilities to add value to its service as a subcontractor. “I think remote-operated equipment in unsafe areas is making a huge impact,” Turner explains. “I don’t think it’s any one thing, though. I don’t think autonomy is going to make operations safe on its own, because you’re still going to have humans on site.” This culture led Turner Mining Group to some great opportunities over the years, primarily working with established organisations in mining and developing miningdigital.com

TURNER MINING

“ WE TALKED ALL DAY ABOUT OUR VALUES, NOT ABOUT THE NUMBERS OR PRODUCTION RATES OR EQUIPMENT” KEATON TURNER

PRESIDENT AND CEO, TURNER MINING GROUP

its relationship with them to provide longterm contractual work, making it a strategic partner for outsourcing machine power. “We’ve had some customers take big chances on us as a young company. We’ve got a customer right now which entrusts its whole operation to us. And this is a multi-billion-dollar-per-year operation. And to have someone believe in our company and what we’re doing, I just feel truly blessed to be a part of it, honestly.” Moving forward, the company is seeking out much larger boots to fill, but in doing so, hopes to create a culture that will shape the lives of many. Through safer practices, leveraging technologies to enhance the procedures that it puts in place, the company is focused on supporting the people of Turner Mining Group and equipping them with the tools and knowledge to drive the company forward.

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NEXT STEP TO

NET ZERO COPPER MINING We speak to John Fennell, CEO of the International Copper Association Australia Ltd (ICAA), about its recently-published minerals processing roadmap

WRITTEN BY: JOHN O’HANLON 30

October 2023

NET ZERO

G miningdigital.com

October 2023

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opper is already playing a transformative role in Australia’s low-carbon future and is critical to transforming its energy systems. Growth in copper demand is driven by a range of interrelated forces, including technology improvements and uptake of renewable energy and low-carbon systems, combined with global policy ambition and favourable regulatory settings that support a low-carbon future. ICAA’s Roadmap to Zero project is a multichannel collaboration between copper industry stakeholders supported by the New South Wales government. In the initial report, the Report Overview launched in 2020, ICAA identified five key themes – Water, Material Movement, Mineral Processing, Ventilation and Discovery. The latest report, Minerals Processing, is the third of the five technical

“ The industry recognises the great demand for copper to underpin our sustainable future” JOHN FENNELL

CEO, INTERNATIONAL COPPER ASSOCIATION AUSTRALIA LTD

Emission Impact Themes identified in the 2019 Zero Emission Copper Mine of the Future Project. The report was launched on 26 July by the Hon. Courtney Houssos MLC, NSW Minister for Finance and Minister for Natural Resources, and is supported by the European Copper Institute (ECI), Aeris Resources, Anax Metals, CMOC – Northparkes Mines, Copper for Tomorrow CRC bid, Glencore, MMG, Newcrest Mining, Newmont, Ok Tedi Mining Limited (OTML), PanAust and Sandfire Resources. A Collaborative Blueprint for Sustainable Mining The ICAA’s Roadmap is a call to action. “The CollaborateOre digital knowledge platform will enable engagement with researchers, universities, technologists, and mining equipment, technology and services (METS) companies across the world,” John Fennell says. This platform serves as a catalyst for transformative change, fostering a collaborative environment that transcends geographical and sectoral boundaries. “Different industries will be able to contribute using the platform to share and work together to solve some of the most important technology challenges the industry faces in getting to Zero Emissions by 2050,” he adds. This ethos of collaboration is deeply embedded in the new report, which has attracted support from a diverse range of stakeholders. “The report accepts it is miningdigital.com

NET ZERO

a difficult journey, however we know for a fact that going electric and switching to renewable energy and alternate fuels will be huge contributors. But to truly achieve our dual targets of profitability and sustainability, mines must take swift action and make significant operational efficiency improvements.” Five cornerstones of mineral processing innovation The report identifies five mineral processing themes with accessible solutions for now and into the future: comminution, concentration, extraction, resource optimisation, and recovery and process optimisation. These cover emerging processing solutions: digital and automation technologies like artificial intelligence (AI), mixed realities or machine learning applied across comminution, concentration, extraction, or waste stream processes to better optimise ore liberation, enrichment, recovery, sustainability and asset performance. Optimising energy, waste, water use and equipment performance at sites can be achieved through cutting-edge grinding, flotation, leaching, ore chemistry, process optimisation and advanced recovery solutions. Future innovations are widereaching and include coarse particle flotation, gravity separation, microwave fracturing, novel leaching, bio-mining, artificial neural networks and ESG mapping. “We identify the key steps in copper mineral processing and then drill down to the ways we are going to become more operationally efficient and therefore produce lower CO2 emissions,” Fennell explains. The roadmap 34

October 2023

is full of innovative solutions, covering everything from artificial neural networks and bio-mining to ESG mapping and advanced recovery solutions. Each theme is a building block towards a more sustainable and efficient mining operation, promising not just environmental benefits but also operational excellence. AI a game-changer in mineral processing AI is poised to play a transformative role in achieving the report’s objectives, as Fennell outlines. “I am sure everyone can imagine how AI is going to change our industry, but in simple, practical terms we are underpinning our digital knowledge platform with a large language model (LLM) technology that

LOGISTICS NET ZERO

will enable vast amounts of research to be summarised, linked, and presented to mining executives to help them become topic experts on various areas of their mine in the shortest possible time. They can then reach out to global experts working on the platform to be included in current and future deep dive research programmes.” Typically, processing plants have terabytes of data stored over several years that can be combined with financial and market data to gain unique insight into profitability under different scenarios. Several pioneering operators are starting to harness AI, not only to resolve short-term challenges, but also to enhance operational resilience as a longterm competitive advantage.

John Fennell TITLE: CEO COMPANY: INTERNATIONAL COPPER ASSOCIATION AUSTRALIA LTD INDUSTRY: COPPER MINING LOCATION: SYDNEY, AUSTRALIA Fennell has been the CEO of the International Copper Association Australia since 1998, with the association currently representing the majority of copper producers in Australia

About ICAA The International Copper Association Australia is the peak body for the copper industry in Australia, representing some of the country’s most influential companies in mining, manufacturing, production and recycling. The International Copper Association Australia supports the activities of its members through the promotion of copper here and overseas, and helping to identify and develop new market opportunities, especially in the Asia Pacific region. By bringing together key industry stakeholders at a senior level, the International Copper Association Australia provides a forum to facilitate the coordination of policy, research, knowledge, marketing and business strategies. Expertise that we make available to everybody right across the copper industry in Australia, from the CEO of a major mining company to the electricians and plumbers working with copper products on a daily basis. The public face of the copper industry, the International Copper Association Australia also acts as an informed advocate with government, the community and the media, managing a wide range of public information and targeted education. A toll free information line, the Internet and a free, state of the art copper library are just some of the activities that support copper in the community everyday.

“ We identify the key steps in copper mineral processing to make the process operationally efficient and therefore produce lower CO2 emissions” JOHN FENNELL

CEO, INTERNATIONAL COPPER ASSOCIATION AUSTRALIA LTD

Australia in the global copper ecosystem Australia is a leading player in the global copper market, Fennell says. “Australian copper mines produced some 830,000 tonnes of copper in 2022, and are on target to produce more than 1m tpa in the next few years. Australia has the second largest copper reserves and is the seventh largest producer of copper worldwide and there are 33 operational mines spread across the country. South Australia is home to four operational mines and holds the lion’s share of Australia’s reserves of copper with 69%, followed by New South Wales with 12%, and Queensland and Western Australia with 9%.” Fennell also touches on the Copper Mark programme, which has the goal of certifying all mines that meet the UN Sustainable Development Goals. “The industry recognises the great demand for copper to underpin our sustainable future, and

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we have already started the Copper Mark programme to certify mines that are meeting the UN Sustainable Development goals, which include fighting poverty, contributing to regional economies and positive action to mitigate climate change. 25% to 30% of copper mines worldwide are now in this programme and in time we foresee most mines will certify.” This is a clear indication that the industry is not just paying lip service to sustainability, but is actively working towards it. The ICAA’s roadmap is a strategic action plan aimed at revolutionising the copper mining industry. “Copper is key to a greener, smarter world, but mining has to embrace innovation to cut emissions going forward,” Fennell asserts. “With its multi-stakeholder approach and focus on innovation, the ICAA has laid the groundwork for a future where copper

mining is not just a major contributor to our economy, but also sustainable and environmentally responsible.” The new report and its initiatives are visionary and actionable. “The Mineral Processing report suggests just what can be done together,” Fennell concludes. It’s a collective endeavour, a shared journey towards a future where copper mining in Australia and beyond is both sustainable and prosperous. With the roadmap as a guide and the CollaborateOre platform as a catalyst, the ICAA is leading the industry into a new era of sustainability, innovation and collaborative success. This roadmap serves as a blueprint for the industry, offering a comprehensive, actionable plan that promises to transform copper mining into a sustainable, profitable, and environmentally responsible enterprise. miningdigital.com

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TECHNOLOGY

THE LOOMING CRISIS IN RARE-EARTH METALS BCG’s Tom Butler warns that a shortage of key minerals will hamper the development of new technologies and the delivery of green energy WRITTEN BY: JOHN O’HANLON

October 2023

s the world pivots towards a greener future, the focus has largely been on reducing carbon emissions. However, a less-discussed but equally pressing issue is the looming shortage of rare-earth metals, crucial for green technologies. A recent article by Boston Consulting Group (BCG) warns that the global demand for rare earths is expected to reach 466 kilotons by 2035, up from 170 kilotons in 2022. Tom Butler, Senior Adviser at BCG, formerly CEO of the International Council on Mining and Metals (ICMM) and a key contributor to the article, emphasises the gravity of the situation: “The main point of the article is to highlight an expected critical shortage of rare earths in the near to medium term, which threatens our ability to achieve our decarbonisation objectives. The shortage is compounded by the fact that China dominates the existing supply chain, as a result of which the market is subject to geopolitical risks. It seems increasingly clear that we will not be able to achieve the Paris Agreement’s target of limiting temperature increases to no more than 1.5 degrees above pre-industrial levels. We are running out of time on this.” The Complexity and Geopolitics of Rare-Earth Mining Rare-earth metals are not as rare as their name suggests: the challenge lies in their extraction and processing. “Their processing is extremely complex, requiring very skilled personnel,” Butler notes. “And the development lead time can be long – at least five years, depending on the location of the deposit, and considerations such as the nature of the ore body, logistics, and the fiscal, legal and permitting framework.” The BCG article suggests that more than miningdigital.com

sustain peak performance.

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“ Rare-earth metals are not as rare as their name suggests: the challenge lies in their extraction and processing” TOM BUTLER

SENIOR ADVISER, BCG

20 new rare-earth projects need to be launched immediately to avoid a shortage by 2030, with an additional ten projects needed by 2035. It also highlights the need for a US$30 billion investment in the upstream stage alone from 2022 to 2035.

Neodymium is a magnetic chemical element with the symbol Nd, in solid state. It is part of the rare earth group, used in the technology industry

China currently dominates the rare-earth supply chain, posing significant geopolitical risks. Butler recalls the 2010 price spike when China restricted supply to Japanese manufacturers following a political dispute. “I think this is one of the key preoccupations of western countries,” he says. The article also highlights the role of market dynamics in the rare-earth industry. For instance, the price of neodymium oxide needs to be at least $150 per kilogram for a midstream project to be profitable. However, prices have never exceeded this threshold for any significant period. miningdigital.com

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A comprehensive plan to avert the crisis BCG’s five priorities for immediate action:

Create Enabling Conditions: Governments should foster the development of new mines through fiscal incentives and streamlined permit processes. For example, Canada has set aside as much as $3bn to facilitate and support new mine applications and development.

Target Investments: Quasi-government and multilateral entities could provide investments, loans, or guarantees to new projects. “These entities can be effective vehicles for funding these rare-earth mines.”

Improve Transparency: Public-private groups like France’s Observatory of Mineral Resources could provide valuable data for decision-making. “By collaborating, members in a public-private group could monitor and chart both the production of

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critical-mineral projects at various stages of development and the downstream companies that may buy the elements.”

Forge Partnerships: Regional alliances and private partnerships can share the effort and risk involved in rare-earth sector growth. “A multinational consortium could establish a mine in Australia, processing capabilities in Europe, and downstream production in the USA - with financing and output equally divided among the participants.”

Develop Recycling Programmes: Governments should establish standards and incentives for recycling rare-earth elements. “Recycling can increase the amount of rare earths available for manufacturing permanent magnets and create a new source of supply of these scarce commodities.”

“The rare-earth shortage may not be uppermost in people’s minds now, but it must be resolved” TOM BUTLER

SENIOR ADVISER, BCG

Butler, meanwhile, is an advocate of global collaboration. “Although governments were initially slow to take action on this, it is encouraging to see there is now broad acknowledgement of the challenge. Over the last few years many countries have articulated critical minerals strategies. Some countries, like the USA, are directly supporting the private sector in this area with equity investments. And as the article highlights, the French have established an “observatory” to develop technical and economic solutions in the critical minerals sector. I do think there is a pressing need

for still greater collaboration and also a global knowledge centre and ‘warehouse’ for information exchange. We have an International Energy Agency but this does not yet exist for mining.” The Human and Environmental Costs While the focus is often on the economic and geopolitical aspects, it’s crucial to also consider the human and environmental costs of rare-earth mining. It is essential that any new mining projects adhere to the highest standards of environmental protection and social responsibility. miningdigital.com

Controlled explosion on open pit mine

“ The shortage is a ticking time bomb that requires immediate and collaborative action” TOM BUTLER

SENIOR ADVISER, BCG

“Companies should engage with local communities and invest in sustainable mining practices to mitigate the environmental impact. The industry has a responsibility to ensure that the extraction of these critical minerals does not come at the expense of local ecosystems or communities.” 46

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This added layer of complexity makes the call to action even more urgent. As we strive for a greener future, we must also ensure that the path we take is sustainable and just, not only for the global community but also for the local communities directly affected by these mining activities. It’s a tall order, but one that we cannot afford to ignore.

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A ticking time bomb The rare-earth metals shortage is a ticking time bomb that requires immediate and collaborative action from both governments and the private sector. As Butler puts it: “In my view a much higher level of priority needs to be allocated to this issue. At the most strategic level, a far greater degree

of international cooperation is required, as we have highlighted in the article.” The BCG article’s key takeaways underscore the urgency of the situation: the global 2050 carbon emissions targets may be eclipsed by a rare-earth supply-demand imbalance unless swift, aggressive and purposeful action is taken. Upstream mining operations should be initiated immediately, and collaboration among public-private groups, regional and private partnerships, and industry consortia is crucial for risk-sharing and transparency. The time to act is now. The rareearth shortage may not be uppermost in people’s minds, but it must be resolved— or it will become a bottleneck, significantly limiting the world’s chances to meet its carbon emissions goals. Butler concludes: “The rare-earth shortage may not be uppermost in people’s minds now, but it must be resolved – or it will become a bottleneck, significantly limiting the world’s chances to meet its carbon emissions goals. “By 2035, we expect to need roughly three times the current level of demand for rare earth magnets. As we have highlighted in the article, we will need roughly 30 new projects by 2035 in order to meet this demand. We are a long way from achieving this.” This article’s analysis serves as a call for immediate action. The stakes are high, and the window for effective action is rapidly closing. It also serves as a blueprint for governments and industry stakeholders on how to navigate this complex issue. It’s not just about securing a supply of rareearth metals; it’s about securing our future. With the clock ticking, the question is not whether we can afford to act, but whether we can afford not to. miningdigital.com

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