As the mining and resources industry winds down for the year and the festive season settles in, Mining.com.au is unwrapping a 12-day Christmas series unwrapping the forces shaping the sector.
Much like the classic carol, each day builds on the last. On the eighth day of Christmas, the focus turns to the gifts that are not wrapping gold in foil, but are arriving in circuits and data streams.
Across the industry, technology is no longer just an enabler. From exploration to extraction, safety to sustainability, a new suite of digital and physical innovations are transforming how the sector operates.
Lighting the way: AI
The first big technology – artificial intelligence (AI) – is rapidly becoming one of mining’s most-talked about and powerful tools.
Mining is considered one of humanity’s oldest endeavours and, despite its age, the industry is at a point where transformation and technological revolution is essential to meet the growing demands for all commodities necessary to the global energy transition.
In exploration, AI systems are analysing geological, geochemical and geophysical datasets at a scale no human team ever could.
Opawica Explorations (TSX-V:OPW) is one example of explorers combining the power of AI with traditional geoscience to identify discoveries.
CEO Blake Morgan says with advanced data and an expanded campaign, the company is prepared to show the market the true scale of the Arrowhead Project’s potential, located in Canada, as reported by Mining.com.au.
The AI method integrates millions of dollars worth of geological data across a high-resolution 5m by 5m by 5m grid, delivering precision in mineral targeting.
Mining giant BHP (ASX:BHP) has also been using AI as a tool to unlock value through innovations such as predictive maintenance, energy optimisation, autonomous vehicle and machinery operation, data-driven decision making, and real-time monitoring and reporting.
Despite its powerful use within the mining sector, Leviathan Metals (TSX-V:LVX) CEO Luke Norman notes that an AI search uses about 10 times the amount of computation than a traditional Google search requires.
“So as that continues to grow, the demand on copper continues to grow, and the supply is becoming more and more constrained,” Norman says.
AI computing is the use of specialised hardware and software to power AI systems. Hewlett Packard Enterprise reports that it enables machines to perform tasks that mimic human intelligence by processing vast amounts of data to learn, reason, and make decisions.
“AI is using multiple sources from the web, so it is a far more power consuming way of doing things. And then that’s just doing a search through AI – it has far more attributes to it than just replacing Google search,” Norman adds.
Autonomous steering sleighs
Autonomy is also no longer experimental. Rio Tinto’s (ASX:RIO) Autonomous Haulage system, now one of the world’s largest, has moved billions of tonnes without a driver.
Commonly referred to as a self-driving or driverless vehicle, an autonomous vehicle is a type of vehicle that is capable of navigating and operating without human intervention. These vehicles use a combination of advanced technologies and sensors to identify their environment, make decisions, and control their movement.
The mining giant runs more than 130 autonomous trucks across its iron ore operations. The trucks are operated by a supervisory system and a central controller. The system uses pre-defined GPS courses to automatically navigate haul roads and intersections and knows actual locations, speeds, and directions.
In 2018, each truck was estimated to have operated on average 700 hours more than conventional haul trucks, with 15% lower costs.
According to Grand View Research, the global autonomous vehicle market size was estimated at US$68.09 billion ($104.13 billion) and is projected to reach US$214.322 billion by 2030, growing at a compound annual growth rate of 19.9% from 2025 to 2030.
McKinsey reports that the total cost of ownership (TCO) for autonomous heavy-duty trucks could be reduced by up to 42% per mile, particularly for long-haul routes exceeding 1,500 miles. These savings stem from reduced labor costs, lower fuel consumption, and fewer accidents.
Santa’s eye in the sky
Once used as a novelty, drones are now essential to the mining sector. Drones, also referred to as remotely piloted aircraft systems or unmanned aerial vehicles, have emerged as a viable solution to improve efficiency, safety and productivity in mining.
Aviation Consulting says from surveying mines to monitoring production and providing intelligence in safety compromised situations, drones are valuable tools in the industry.
Mine drones are equipped with cameras and sensors that allow them to capture data and images from mine sites. These include stereo cameras, hyperspectral sensors, infrared sensors and laser range finders.
These drones are also operated remotely and can be used to fly over and inspect various areas of a mine. They are primarily used to collect accurate drone data that is used for mapping, surveying, asset inspection and planning purposes.
Recently, Krakatoa Resources (ASX:KTA) implemented drones to conduct surveys at the Zopkhito Antimony-Gold Project in Georgia. The company aims to generate data for a maiden resource estimate before furthering resource growth across the greater project area.
Meanwhile, Australian drone technology company Freespace Operations has built a technology – Cooperative Lift – that enables the Callisto 50 heavy-lift drone to balance and safely carry loads up to 100kg, four times what a single drone can manage.
The technology enables Freespace’s Australian-designed and built platform to complete missions previously limited to helicopters or large bespoke airframes. While the drones are currently used in the defence and logistics industries, given their heavy load capacity there could be scope for use in the mining and resources sector.
Callisto 50 is a heavy-lift multirotor drone designed and manufactured in Australia. It originally supported up to 25kg payloads and is built for defense, industrial, and commercial applications.
IoT sees when you’re sleeping
The Internet of things (IoT) has also transformed the modern mine into a connected ecosystem. Thousands of sensors monitor everything, including equipment vibration and energy consumption, as well as tailings stability and air quality.
IoT is commonly heard of in the industry, according to BesTech, as it refers to interconnected physical devices such as computing machines, equipment and sensors to the digital technologies that connect and exchange data.
This connectivity allows operations to predict failures, optimise maintenance schedules, improve energy efficiency, and enhance environmental monitoring.
BesTech says in the mining industry, implementing IoT technology to reduce the need for human intervention will have impacts on the future of the industry.
For example, when a blast is performed to open up a new site within the mine, sensors can be used to determine whether the area is cleared of toxic air and debris. IoT can also track the locations of mining equipment.
Major mining companies that use IoT include Anglo American (LSE:AAL), BHP, Fortescue (ASX:FMG), and Rio Tinto.
Earlier this year, mining services provider NextOre made a “world-first sensor system” which is available to underground mines. Initially the unit will be used for between 30 to 50 tonne mine trucks, with the potential to expand applications to load-haul-dump bucket loads, further enhancing underground efficiency.
NextOre says the sensor also provides insights to enhance overall productivity while reducing operations costs and environmental impact.
Santa’s digital workshop
The fifth, digital twin technology, is changing how mines are designed, tested, and operated. By creating a virtual model of a mine, updated in real-time using operational data, mines can simulate hundreds of scenarios without disrupting production.
Digital twin integrates data from sensors, IoT devices, and other sources to simulate processes.
BHP says mining operations are “highly complex”, often involving multiple mines, hubs, railways, ports, conveyors, loaders and trains – all working together.
“With so many moving parts, it’s impossible for humans alone to optimise every decision,” the company says.
“By combining digital twins with GenAI, we can process vast amounts of data to make better decisions to improve our productivity, reduce our costs and environmental impact, and make our operations safer.”
Through a digital twin and GenAI BHP is able to analyse its historical data and current mine plans and operating context to predict realistic production outcomes.
If these predictions identify production risks, we can take swift action to mitigate them. For example, a digital twin can identify the location of a bottleneck and help us decide how to address the root causes. Testing ‘what-if’ scenarios within the digital twin saves time and cost and is safer as we require fewer on-site trials.
BHP is using digital twins at BMA, Copper South Australia, and Escondida to predict production outcomes and uncover key performance drivers, risks, and opportunities.
The Australasian Institute of Mining and Metallurgy (AusIMM) says there are four types of digital twins – analytical, asset, process, and system twins.
Analytical twins delve into data intricacies to extract actionable insights, while asset twins provide practical solutions examining machinery behaviour, facilitating proactive maintenance and prolonging asset lift.
Process twins target inefficiencies to empower industries to achieve higher levels of productivity and help inform better decision-making, while system twins navigate intricate systems enhancing performance and uncovering opportunities.
Silent nights, electric rides
Battery-electric mining equipment is the sixth technology being more used within the sector. The trend is driving lower carbon emissions, reduced diesel usage, lower heat load, and improved operator health.
The importance of electrification is increasing throughout the sector due to better health and safety conditions for workers and lower costs.
Zero diesel emissions contribute towards an environment that is healthier and safer for operators, while also less heat output results in lower costs for ventilation and cooling, which, when combined with higher acceleration, operating speed and loading times, provides a strong business case.
AusIMM principal consultant at Snowden Optiro, Sarah de Vries, says miners have a range of options available to cut scope one carbon emissions and start making a bigger dent in the estimated 8% of global greenhouse gas emissions generated by the industry.
McKinsey & Co adds that between 40-50% of this comes from diesel combustion in mobile equipment at more than 15,000 mines. Major surface iron ore and underground copper and base metal mines have placed record orders for battery-electric equipment in 2024 and 2025.
In 2019, Newmont’s (ASX:NEM) Borden mine in Ontario became the first underground gold mine in Canada to transition to a fully battery electric fleet, while Bellevue Gold (ASX:BGL) recently produced the world’s first ‘net zero gold’.
Bellevue’s 90 megawatt (MW) hybrid station combined 24MW of wind, 27MW of solar, 24MW of thermal generation, and a 15MW, 29MW per hour battery. The site has recorded 58 consecutive hours on 100% renewable power in June and now targets 80-90% renewable penetration over a typical year.
Major Swedish mining equipment manufacturer Epiroc, which has supplied more than 600 battery electric vehicles (BEVs) at over 30 sites, aims to have a battery-electric version of every machine in its current portfolio available by 2030.
Canadian MacLean Engineering, supplier of more than 100 underground BEVs to North American mines since 2015, says nearly half the companies based in the region doing new project feasibility studies are requesting BEV quotes.
Safety tech gifts
The seventh technology – smart helmets – has entered into mining’s new digital age. These safe, wearable protection items of clothing are becoming more adopted across high-risk environments, particularly underground.
IEEE Xplore reports that when it comes to dangerous working conditions in deep mines, a real-time and instantaneous monitoring and warning system is essential to boost safety.
If a worker gets stuck in a tunnel, then this detection system detects the worker using an RF signal and Wi-Fi.
The sensors are attached to the worker’s helmet. As the worker moves through the tunnel, sensors on the helmet detect flammable gas (LPG) and send a signal to the exit station via Wi-Fi. It is connected to the external control room in a tunnel via Wi-Fi.
Instead of reacting after incidents occur, safety teams are able to identify risks early and intervene before injury happens. Safety is no longer about hard hats – it becomes about smart data.
An advanced Christmas
The final technology unwrapped is advanced mineral processing technologies which are improving recoveries and reducing environmental footprints. As global ore grades continue their decline, miners are being challenged to become more efficient in how they extract minerals.
Some of the benefits of advanced mineral processing technologies, sensor-based ore sorting, AI-optimised comminution circuits, hydrometallurgy and bioleaching, dry stacking and water recycling technologies.
Around 100 researchers in the Commonwealth of Scientific Industrial Research Organisation’s (CSIRO) mineral processing program are developing cutting-edge technologies to transform minerals into the foundation of a “sustainable tomorrow”.
CSIRO’s focus is on purifying graphite for battery anodes, with the potential for commercialisation. The organisation says another is a pilot plant, producing materials that can go on to become cathodes – the other half of a lithium-ion battery.
The chemical process reduces the environmental impact and health risks compared to traditional methods. CSIRO notes how evolving a process from the lab bench to an industrial scale reinforces how impactful the research can be in shaping a more sustainable industry.
What ties these eight technologies together is integration. AI feeds digital twins, IoT powers autonomy, electrification reshapes processing, and drones supply data to AI models.
Mining isn’t just adopting technologies, but it is building interconnected systems. Or as the Christmas carol goes, the eight maids aren’t just milking cows but they’re milking efficiency, data, and innovation.
Write to Aaliyah Rogan at Mining.com.au
Images: Opawica Explorations, Volvo, Rio Tinto, BHP, Krakatoa Resources, Freespace Operations, & Mining.com.au
