Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY

Page created by Sandra Jacobs
 
CONTINUE READING
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
Will electrification
     spark the next
     wave of mining
     innovation?

The better the question. The better the answer.
The better the world works.
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
Electrification in
     mining survey
     Electrification of mines is climbing the agenda of mining
     companies as a driver of cost reduction, energy efficiency
     and license to operate stewardship. But, reaping the full
     benefits of an electrified mining future will require
     reskilling, reaching out across sectors and rethinking the
     fundamentals of mine design.

2   | Will electrification spark the next wave of mining innovation?
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
Executive summary
To uncover both the opportunities and challenges of electrification, we commissioned a survey of miners and original
equipment manufacturers (OEMs) with the Sustainable Minerals Institute at The University of Queensland (Australia)
and The Norman B. Keevil Institute of Mining Engineering at The University of British Columbia (Canada). Four key
themes emerged:

1                                                                   3
Electrified mines improve                                           Collaboration will unlock better
economics and strengthen license                                    electrification solutions.
to operate.
The cost of energy represents up to one-third of a                  Partnerships and co-creation of solutions with OEMs,
mining company’s total cost base, making it a keenly                other mining companies and governments are needed
managed component of operations. In addition, demand                to successfully integrate electrification in mines.
for carbon reduction in the sector is inevitable, and
electrification is one way to achieve it. Diesel engines
cannot be replaced with carbon-generating electricity
and, therefore, electrification needs to be accompanied
with a move to renewable power.

2                                                                   4
Electrification needs                                               Mine design needs a rethink to build
different skills.                                                   in optionality for future innovation.
Mine electrification requires different worker skills as it         Decoupling mines from diesel is not an easy task, mainly
enables other advanced technologies. In developing                  due to the diverse range of technical and financial
economies, this challenges the assumption that a mine               challenges in mining various deposits, which make a
provides employment for laboring workers.                           “one-size-fits-all” solution hard to find. Getting full value
                                                                    out of electrification means developing a technology
                                                                    road map in parallel with the mine plan. It is important
                                                                    to start thinking about building agility into mine design
                                                                    to leverage the potential benefits in asset flexibility,
                                                                    lower ventilation requirements and the human
                                                                    footprint.

The future of electrification in mines requires a paradigm shift to embrace new emerging technologies.

                                                                              Will electrification spark the next wave of mining innovation? |   3
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
Our survey                                    The Sustainable Minerals Institute at The
                                                    University of Queensland and the Norman
                                                                                                 underground mining, vice president (VP)
                                                                                                 – product line, senior project manager –

         sample
                                                    B. Keevil Institute of Mining Engineering    technology, executive head of technology
                                                    at The University of British Columbia        operations, head of technology, chief
                                                    undertook extensive interviews of mining     innovation officer, VP – sustainability and
                                                    companies and OEMs located in Australia,     director of digital technology.
                                                    Canada, Colombia, New Guinea, Peru,
                                                    Russia, South Africa, Sweden, the UK and     The EY organization has anonymously
                                                    the US. These companies have operating       quoted these participants throughout the
                                                    mines in all continents except Antarctica.   report. EY teams would like to thank all
                                                                                                 the interviewees for their participation
                                                    The job roles of the interviewees included   and their candid insights.
                                                    CEO, CFO, COO, global head of

4   | Will electrification spark the next wave of mining innovation?
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
Electrified                          The cost of energy represents up to                     But, to date, we’ve seen little innovation in
                                     one-third of a mining company’s total cost              providing energy to mines, with
mines improve                        base, making it a keenly managed                        operations largely relying on fossil fuels to
economics and                        component of operations. Average grades                 run equipment and electricity for
strengthen                           have halved and overburden has doubled                  processing. Mines in remote areas are
license to                           over the last 30 years, and, as mines are               most likely to use diesel power
                                     beginning to extend to depths beyond                    generation. For example, by the time a
operate                              current norms, their energy demand is                   Canadian remote diamond mine is
                                     growing even larger. Going electric                     decommissioned, it has consumed more
                                     reduces not only ventilation and                        than 800 million liters of diesel fuel
                                     maintenance costs but also up-front                     (accounting for over 20% of its operating
                                     capital costs. For example, automation                  costs). In addition, renewable energy has
                                     efforts at Resolute Mining’s Syama mine                 simply not been cost effective until
                                     in collaboration with Sandvik have                      recently. But as technology costs have
                                     resulted in lower up-front capex and also               fallen, the uptake of distributed energy
                                     have the potential to reduce life-of-mine               resource has accelerated. By 2040,
                                     all-in sustaining costs by                              renewables will outpace all other sources
                                     approximately 16%.1                                     of energy and account for 60% of all
                                                                                             capacity additions.

                                     5,285GW of net capacity to be added in the period 2018–40

                                              Coal

                                               Gas

                                                Oil

                                         Nuclear

                                    Renewables

                                                   -1                 0                 1                 2                  3                  4

                                                                                                                           Thousands of GW

                                                                          Retirements         Additions

                                     Sources: IEA World Energy Outlook and EY analysis, March 2019.

         1 “
            Resolute Mining’s updated study cuts underground gold mine costs by US$135 per ounce” Mining Capital, https://www.miningcapital.com/
         companies/news/199989/resolute-minings-updated-study-cuts-underground-gold-mine-costs-by-us135-per-ounce-199989.html, accessed 22
         May 2019.

                                                                             Will electrification spark the next wave of mining innovation? |      5
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
The World Health Organization has declared that diesel engine                           outlay is spent on powering gigantic ventilation systems to
 exhaust emissions cause cancer in humans, outlining that diesel                         remove pollutants from tunnels.3 And, diesel engines generate
 particulate matter belongs in the same potentially deadly                               twice as much energy as battery-powered vehicles, making it
 category as asbestos, arsenic and mustard gas.2 This has                                even more necessary to have proper ventilation systems in
 relevance to underground mining, where diesel equipment is                              place. The switch from diesel to electric therefore makes good
 operating in confined areas and workers are subject to                                  economic sense, but critically, it also enables a greater level of
 potentially hazardous exhaust fumes in their day-to-day                                 on-site health and safety.
 operations. As much as 40% of an underground mine’s energy

               “
               The biggest issue I see driving underground
               is human health. Over time, that’s going to
               push us toward electrification. You don’t want
               any accidents at your mine sites, but you also
               don’t want any long-term implications for
               the safety of your workers. So, we’ve got to be
               investing more in terms of the technology to
               provide that safer working environment for
               them. The issues with asbestos are already
               here. I think that the secondary effects of
               diesel particulates are coming.

 Comparison of operating costs for similar diesel and electric load haul dump trucks

                4,50,000
                4,00,000
                3,50,000
CA$ per year

                3,00,000
                2,50,000
                2,00,000
                1,50,000
                1,00,000
                  50,000
                          0
                                             Fuel                      Ventilation                       Maintenance                               Total
                                                                                     Diesel       Electric
 Source: http://minewiki.engineering.queensu.ca/mediawiki/index.php/Electric_equipment.

  2
    “Cancer risk from diesel fumes in underground mines prompts fears of industrial health disaster,” ABC News, https://www.abc.net.au/news/2018-09-15/mining-industry-
  confronted-over-cancer-risk-from-diesel-fumes/10209762, accessed 4 April 2019; “Diesel cancer risk in WA mines ‘worse than asbestos,’” Perthnow, https://www.perthnow.
  com.au/news/diesel-cancer-risk-in-wa-mines-worse-than-asbestos-ng-f4d6ebea31d42746f1a67053c0e3429b, accessed 4 April 2019.
  3
    Electric vehicle revolution goes underground with mining trucks,” Mining Weekly, https://www.miningweekly.com/article/electric-vehicle-revolution-goes-underground-with-
  mining-trucks-2018-11-14/, accessed 2 July 2019

6              | Will electrification spark the next wave of mining innovation?
Will electrification spark the next wave of mining innovation? - The better the question. The better the answer. The better the world works - EY
Improving economics and the benefits of license to                      based equipment in their mine plans. Tony Makuch,
                             operate are driving more companies to consider                          CEO of Kirkland Lake Gold, said, “Ten years from
                             electrification, and some have already begun this                       now, I’d think we’ll go from 90% to 100% reliance on
                             journey. Remote mines without access to the grid are                    diesel at some mines to less than 20%, the rest will
                             mostly continuing with conventional sources of                          be using batteries. If all the equipment was
                             energy, but, for those connected to electricity,                        developed now, I’d want to pretty much convert all
                             electrification increasingly makes economic sense.                      our mines at once.”4
                             Most new mines are considering including battery-
                              Case Study

                                                      Canada’s first all-electric operation and the world’s first diesel-
                                                      free hard rock mine: Newmont Goldcorp’s Borden mine5
                                                      Newmont Goldcorp’s Borden mine uses a                    • Reduction in annual greenhouse gas
                                                      full range of electrified equipment,                       (GHG) emissions of 70%
                                                      including load haul dump trucks, drills,                 • Reduction in ventilation costs of 50%
                                                      bolters and personnel carriers. According
                                                      to Newmont Goldcorp, electrification at                  • Improved staff well-being
                                                      Borden has resulted in benefits that                     • Reduced megawatt hours of 33,000
                                                      include:                                                   per year because of the huge decrease
                                                                                                                 in ventilation requirements
                                                      • Improved safety performance

                                                      “
                                                      We’ve already surveyed the first group of workers that
                                                      started at our Borden mine,” says John Mullally, Newmont
                                                      Goldcorp Group Executive for Sustainability, North
                                                      America. “Something like 90% said that they would not
                                                      want to go back and work in a traditional underground mine
                                                      alongside diesel engines. Even though they had to adapt
                                                      to some of the new equipment and technology at this mine
                                                      site, they said that the noise level and the air quality inside
                                                      meant this is where they want to stay. They would encourage
                                                      people to go and work underground at these types of mining
                                                      operations, because they feel that it’s a safer and better
                                                      working environment for them.

  Even the World’s Biggest Miners Are Switching to Electric Vehicles,” Bloomberg Quint, https://www.bloombergquint.com/business/bhp-biggest-miners-are-starting-to-drive-
4 “

evs-deep-underground, accessed 4 April 2019.
5
  “Borden: the ‘goldmine of the future,’” World Gold Council, https://www.gold.org/about-gold/gold-supply/gold-development/positive-impacts-mining-case-studi es/borden-
gold-mine-of-the-future, accessed April 2019.

                                                                                                    Will electrification spark the next wave of mining innovation? |       7
Electrification                                      Electrification will accelerate automation                 For example, as the skills gap grows, Rio
                                                           and the internet of things (IoT), as more                  Tinto’s US$2m vocational education and
      needs different                                      reliable electric motors require less                      training initiative, Resource Industry
      skills                                               maintenance and human intervention.                        Collaboration group, has delivered the
                                                           With electrification, automation through                   first nationally recognized course in
                                                           drones, autonomous vehicles and                            automation. This will ensure the next
                                                           remote-controlled operational systems will                 generation of workers is ready for
                                                           be rolled out more widely across mining                    mining’s brave new digital world.7
                                                           operations. There will be increasing
                                                           demand for data and digital literacy skills                Technological advancement and
                                                                                                                      innovation in the industry do not

“
                                                           across all phases of the mining value chain
                                                           that will redesign most occupations as the                 necessarily correlate to an immediate
                                                           human-to-machine interface evolves and                     reduction in the workforce, but it will
We are generating                                          becomes more prevalent. By better                          change the skills required. For example,
opportunities for our current                              understanding the future skills required,                  “driverless trucks” will result in shifting
and future workforce to gain                               industry stakeholders will be able to                      skill profiles from heavy-license drivers,
                                                           strategically plan their workforce and                     to employees with data processing, digital
skills and competencies                                                                                               literacy and technical planning skills. A
                                                           sustain their competitive advantage in
for smart mining. The new                                  global markets. However, to achieve this, a                recent EY report, commissioned by the
curriculum will enhance the                                significant investment and an adaptive                     Minerals Council of Australia8, found that:
capability of those in the                                 workforce will be required.                                • Employment projections are set to
mining sector and form part                                Skills such as change management,
                                                                                                                        increase over the next five years and
                                                                                                                        approximately 77% of occupations in
of the learning pathways                                   managing innovation, systems
                                                                                                                        the sector will be enhanced or
for those seeking to enter a                               engineering and digital technology are                       redesigned due to technology.
range of industries, applying                              required to break employees out of silos.
                                                           At the same time, mining companies and                     • Skills with growing demand include
automation and technology.                                 universities need to communicate changes
                                                                                                                        system evaluation and analysis,
By working with South                                                                                                   mathematics, active listening,
                                                           in required skillsets and collaborate to
                                                                                                                        instructing, data analysis, data and
Metropolitan Technical and                                 develop future courses. In 2018, the                         digital literacy, and judgment and
Further Education and the                                  number of mining engineers continued to                      decision-making.
                                                           decline, with only 34 first-year
Western Australian State                                   enrollments across the four Mining                         • Skills with decreasing demand include
Government, we will deliver                                                                                             vehicle operations, materials extraction,
                                                           Education Australia universities, which
                                                                                                                        operations and control, equipment
the courses that will prepare                              supply 80% of Australian mining
                                                                                                                        maintenance and blast-hole drilling.
young West Australians for                                 engineering graduates.6 This shows a
                                                           declining supply of workers and also                       For employees, the ability to transition,
the jobs of the future.                                    indicates that universities need to develop                upskill, cross-skill and reskill will be
                                                           and deliver education and training options                 essential, while companies will need to
Chris Salisbury                                            with new and existing partners to increase                 provide employees with the platform to
Chief Executive, Iron Ore, Rio                             the future pipeline, as well as provide                    do this. Innovation has changed the
                                                           opportunities for the existing workforce.                  modality of work — from mine site to
Tinto.
                                                                                                                      remote and integrated operating centers.

6
  “The Future of Work: The Changing Skills Landscape for Miners — A report for the Minerals Council of Australia,” https://minerals.org.au/news/powering-future-australian-
mining-people-innovation-and-modern-education, accessed 4 April 2019.
7
  “Machine learning: Australia’s first automation course launched at WA TAFE,” Sydney Morning Herald, https://www.smh.com.au/business/workplace/machine-learning-
australia-s-first-automation-course-launched-at-wa-tafe-20190612-p51ww4.html, accessed 24 June 2019
8
  The Future of Work: The Changing Skills Landscape for Miners — A report for the Minerals Council of Australia,” https://minerals.org.au/news/powering-future-australian-
mining-people-innovation-and-modern-education, accessed 4 April 2019.

8   | Will electrification spark the next wave of mining innovation?
This brings benefits that include increased employee                     requiring a higher level of thinking to anticipate and
                             safety, improved recruitment and retention, and                          plan activity and manage the human-to-machine
                             more efficient operations. Moving workers to a safer                     interface. For example, automation efforts at
                             environment closer to communities can also attract                       Resolute Mining’s Syama mine in Mali have not led to
                             different types of employees, allowing for greater                       any job losses but have created more training
                             diversity. In these new digitally powered workplaces,                    opportunities for local workers to operate at higher
                             employees will move from routine tasks to roles                          levels.9

                                                      "Helping communities thrive well after                  with government on their country vision
                              Case Study

                                                      the mine is gone” Anik Michaud, Group                   and with academia on the creation of
                                                      Director of Corporate Relations, Anglo                  the right skills. The company is
                                                      American.10                                             focused on:

                                                      At the Investing in African Mining Indaba               • Moving from a social license to
                                                      2019 conference, Mark Cutifani, Anglo                     operate to a social license to innovate
                                                      American’s CEO, described a future                      • Creating a sustainable jobs program in
                                                      scenario where five off-site, non-mining                  collaboration with academia
                                                      jobs are being targeted for every one
                                                                                                              • Upskilling or reskilling employees
                                                      on-site mining job. The plan is to
                                                      advance local communities from                          • Identifying transferrable skills to work
                                                      subsistence farming to commercial                         in any company, industry or country
                                                      agriculture, which will also involve
                                                      helping them to access water. Achieving
                                                      this will involve greater collaboration

      “There’s a lot of work to be
       done to get people up to the
       level needed to maintain
       and service new high-
       voltage electric equipment
       in an environment where
       it can be hot, humid and
       corrosive. That is going to be
       a challenge for everybody.

9
  “Sizing up Syama: the world’s first fully automated mine,” Mining Technology, https://www.mining-technology.com/features/sizing-syama-worlds-first-fully-automated-mine,
accessed 14 June 2019
10
   “Innovation mining’s biggest challenge — Anglo,” Engineering News, http://www.engineeringnews.co.za/article/innovation-minings-biggest-challenge-anglo-2019-02-04/
rep_id:4136, accessed 4 April 2019.

                                                                                                    Will electrification spark the next wave of mining innovation? |     9
Collaboration                                      Mining organizations tend to be risk-                   Johan Söderström, Managing Director of
                                                           averse and conservative, contributing to a              ABB Sweden, “LKAB is taking a whole
        will unlock                                        conventional and typically fixed                        new approach to the development of
        better                                             perception of the value chain and how it                future mines with unique digital and
        electrification                                    should be managed. Miners tend to view                  sustainable solutions. We look forward to
        solutions                                          supplier relationships as zero sum, rather              partnering with LKAB, Epiroc, Combitech
                                                           than exploring mutually beneficial                      and AB Volvo, and contributing our
                                                           opportunities with the potential to                     knowledge of automation and

“
                                                           maximize value for both parties. A more                 electrification of underground mines and
                                                           open perspective around the role of                     services. Digitalization presents
                                                           suppliers as strategic partners expands                 tremendous opportunities and, together
It’s got to be done in
                                                           the possibilities for miners to benefit                 with our partners, we are creating the
partnership. The mining                                    through innovation, cost reduction and                  safe and efficient mines of tomorrow.”11
houses can’t do it by                                      competitive advantage. In the case of
                                                           electrification, miners are clear that they             Data collaboration will be a critical
themselves, and the OEMs
                                                           can’t go it alone.                                      element to mine electrification. But,
can’t do it by themselves.                                                                                         although the benefits of data sharing are
                                                           Interestingly, many of the participants felt            widely publicized, concerns, such as loss

“
                                                           that not only was it time to work more                  of intellectual property, competitive
                                                           collaboratively with OEMs, but it was also              advantage or perceived loss of data
                                                           time to collaborate across the sector and,              monetization-related opportunities, have
I don’t believe that mining                                potentially, in a noncompetitive way.                   created a protectionist attitude toward
companies or OEMs need                                                                                             data from mining organizations, suppliers
to develop the technology                                  Collaboration can create value for both                 and OEMs. This has limited the ability to
                                                           parties. The partnership among Newmont                  unlock the full potential of data-driven
independently. I believe a                                 Goldcorp, Sandvik and MacLean at the                    decision-making:
lot of these technologies will                             Borden mine is an example of this. Future
be commodity technology at                                 mines will be carbon-free, electrified and              • Mining organizations: Mining’s
                                                           autonomous, which will require new                        end-to-end systems rely on a common
the end of the day, so none                                                                                          integrated data model to support
                                                           technologies to be developed and tested
of this should be proprietary                              to ensure that the mining industry will                   related business processes. For
or be seen as a competitive                                                                                          example, optimizing maintenance
                                                           remain competitive. This not only requires
                                                                                                                     planning, scheduling and execution
advantage.                                                 new control systems and equipment but
                                                                                                                     requires an integrated view of
                                                           also efficient management systems that                    equipment performance, asset health,
                                                           meet future demands for a sustainable

“
                                                                                                                     maintenance costs and the economic
                                                           industry. This will need a new type of                    impact to production. The inability to
                                                           collaboration, a digital ecosystem, where                 access, or only partially access, this
When there’s an accident                                   the miners’ and OEMs’ digital systems and                 data compels organizations to explore
at a mine site, we share the                               operations are in sync.                                   alternatives, including moving away
                                                                                                                     from tier 1 OEM providers.
findings across the sector so                              For example, LKAB, Epiroc, ABB,
                                                                                                                   • Suppliers: Suppliers need to
that we all learn from it. If                              Combitech and AB Volvo have joined
                                                                                                                     understand how their equipment is
we’re going to embark on an                                forces in a partnership and are starting a                used to ensure consistency and quality
                                                           unique test-bed in the ore fields of                      of service and achieve greater levels of
innovation strategy that will
                                                           northern Sweden. The implementation of                    customer satisfaction. Suppliers also
improve the overall reputation                             this project will require significant                     require a real-time understanding of
and viability of our industry,                             investment, and the partners are                          equipment performance, operating
we have to start sharing some                              therefore seeking collaboration with more                 behaviors and conditions, and key
                                                           suppliers, the Swedish state, research                    operational KPIs, such as mean time to
of the knowledge that’s going                                                                                        recovery and mean time between
                                                           institutes and universities. According to
to be out there.                                                                                                     failures.

11
     “New world standard for sustainable mining,” Epiroc, https://www.epiroc.com/en-in/newsroom/2018/new-world-standard-for-sustainable-mining, accessed 4 April 2019.

10 | Will electrification spark the next wave of mining innovation?
What does good look like?

European Sustainable Intelligent Mining
Systems for the global mining industry is
a three-year-old Horizon 2020-funded,
European-wide project to create the
digital mine. The project has a total
budget of €16.2m (about US$18.3m),
and Atlas Copco is leading the consortium
of 12 partners, including miners, METs
and universities. The aim is to make a
connected, efficient, safe and attractive
workforce. Existing test sites for
successful demonstration of technologies
are in Germany, Poland, Sweden and
Finland. Technologies include using
battery rigs to reduce diesel emissions
and improve underground air quality and
the use of semi-autonomous battery
vehicles plus 5G technology to link
people, machines and data.12

Battery Electric Vehicles
Underground Project

The Global Mining Guidelines Group and
Canada Mining Innovation Council outline
the recommended practice for the use of
battery electric vehicles (BEVs) in an
underground mining environment. It can
be used by both mining companies and
OEMs in designing and accommodating
BEVs. It aims to strike an appropriate
balance between standardization and
innovation, providing a global scope while
acknowledging that regional differences
exist in standards and regulatory
frameworks.13

                                                            Source: Sustainable Intelligent Mining Systems.

12
     “Sustainable Intelligent Mining Systems,” Bergforsk, http://www.bergforsk.se/wp-content/uploads/2018/05/morgan-rody.pdf, accessed 12 April 2019.
13
  “Recommended practices for battery electric vehicles in underground mining v2.0” Canada Mining Innovation Council, https://gmggroup.org/wp-content/
uploads/2019/01/BEVs-Poster.pdf, accessed 12 April 2019.

                                                                                                    Will electrification spark the next wave of mining innovation? |   11
Mine design needs                                 Reaping the full value of electrification        progressively as technology becomes
                                                        requires a rethink of mine design that           more scalable and cost effective. A phased
      a rethink to build in                             considers a technology road map in               approach also helps limit up-front capital
      optionality for                                   parallel with the mine plan.                     investment for the miner.
      future innovation
                                                        The long-term view is almost like a              The future of electrification requires
                                                        prequalification for near-term work. An          a paradigm shift to embrace new,
                                                        electric mine looks different, and that          higher-risk technologies.
                                                        differentiation will grow optionality in
                                                        mine design, which is critical now. At the       Many of the technologies enabling the

“
                                                        same time though, the mine plan needs a          shift are still at the prototype stage, and
                                                        technology road map, so that technology          getting them from lab to mine will require
                                                                                                         patience — and a new mindset. While
You can change open pit very                            options can be incorporated as they come
                                                        onto the market. It may not be possible to       safety must remain the priority, the
quickly at a small capital cost.                                                                         traditionally risk-averse culture of mining
                                                        predict the operational tactics and assets
But for underground mining,                             for the duration of mine plans, but it’s         must embrace a new commitment to
what you do today will be                               important to start thinking about building       support and shape the development of
                                                                                                         emerging technologies.
there forever. You’re making a                          agility into mine design to leverage the
decision you’re going to have                           potential benefits in asset flexibility, lower
                                                                                                         For example, electric fleets present
                                                        ventilation requirements and the human
to live with for a long time. You                                                                        sector-specific challenges that go beyond
                                                        footprint. This requires a fundamental
                                                                                                         the relative newness of the technology.
can’t mine through it.                                  change in mindset: alternate asset life
                                                                                                         The range of electric haulage vehicles is
                                                        cycle strategies, ownership models and
                                                                                                         limited compared with traditional diesel
But … if you’re developing                              duty cycles.
                                                                                                         equipment and, as a result, charging the
a new mine, then we’ve got                                                                               vehicles without overloading the system
                                                        Companies also need to understand the
all sorts of other degrees of                           risk-reward profile of investing in              adds a layer of complexity. Miners need to
freedom, such as intelligent                            technology and automation, as well as            follow a staggered approach to charge
                                                                                                         vehicles in order to manage the charging
ventilation, much less                                  whether they will be able to generate
                                                        returns or reduce costs and not just             time and minimize downtime.
ventilation and other things
                                                        change the risk profile of their operations.
now that you have this new                              This move toward electrification is
equipment. So, you can                                  happening in phases. A phased approach
actually start changing your                            enables mines to immediately lower costs
capital quite dramatically.                             and carbon footprints, while advancing

12 | Will electrification spark the next wave of mining innovation?
“
                                 There are challenges for both capital and technology
You’ve got to make a call        Making the right capital investment             Ensuring technology remains agile
                                 decisions
on technology, but don’t                                                         Miners must recognize the fact that
get yourself stuck with that     The fundamentals are different in               technology will evolve over the years and
                                 conventional mining projects compared           whatever makes economic sense today
technology for 20 years.
                                 with those that use renewables. A               might not have similar results five years
Acknowledge that in five         renewables-based energy system has              down the line.
years’ time the technology       high capital expenditure (capex) and low
                                 operating expenditure (opex), whereas           Mining and metals continue to lag behind
will be different … It’s a big
                                 conventional projects have                      other sectors in the realm of
leap of faith.                                                                   technological effectiveness. The value
                                 comparatively low capex and high opex.
                                 While it is comparatively easier (and           from technology will only be realized
                                 cheaper) to change open-pit operations,         when companies change how they work,
                                 it takes a lot of investment to make            rather than succumbing to the lure of
                                 changes to underground operations.              individual technology programs and
                                 Decisions around making changes will            pursuing local optimization, which is not
                                 also depend on the stage of the mine            necessarily transformational.
                                 cycle — toward the end of mine life, it may
                                 not make economic sense to invest.

                                                                Will electrification spark the next wave of mining innovation? |   13
“                                                                                        Local energy policy: competitive edge

                                                                      Case Study
You need to look at it from a                                                            or disadvantage?
feasibility level scope and look at
the entire operation … Look at the                                                       Countries implementing policy and regulatory changes
                                                                                         in a move toward carbon pricing and the reduction of
mine plan and consider ... Is that                                                       GHG emissions will have first-mover advantage in
the best way to plan this mine, or                                                       accelerating the electrification or greater use of
should we attack it from a different                                                     renewables in the sector. Both Chile and Canada have
direction with this different thought                                                    announced carbon-pricing schemes in a bid to
                                                                                         incentivize miners to opt for electrification or
process altogether? You’ve got to get                                                    renewable sources of energy. As a result, companies
a task team together of the whole                                                        such as Barrick, Newmont Goldcorp and Rio Tinto have
operation, maintenance and miners,                                                       invested, or have plans to invest, in mine
and geologists, even metallurgists,                                                      electrification.

the whole gamut to come in and                                                           Chile has outperformed other countries in terms of
look at it from a real holistic point                                                    miners adopting renewables, following a law in 2013
                                                                                         mandating that 20% of its energy should be from
of view; otherwise, you’re going to
                                                                                         renewable sources. This law has been so successful
miss those opportunities.                                                                that it recently reset the target to 70%, which is
                                                                                         anticipated to be accomplished by 2050.14 Leading
                                                                                         practices include:

“
                                                                                         • The Zaldivar copper mine in Chile, a joint venture
                                                                                           between Barrick and Antofagasta, has become the
                                                                                           first mine to operate with 100% renewable energy.
Through my career, I’ve seen many
organizations where, when you push                                                       • A floating island of solar panels is being tested in
                                                                                           Chile as a way to generate clean energy and reduce
technologies from the top down,
                                                                                           water loss at mine operations. The experimental
you’ve got people in the field who                                                         “Las Tortolas” power-generating island is being run
probably know better than the people                                                       by Anglo American at its Los Bronces mine.
pushing it to begin with. Then there’s                                                   India and China are also pushing forward with
resistance, and they’re not buying in.                                                   measures to reduce GHG emissions, and South Africa
It has to be their idea for it to really                                                 implemented a carbon tax effective from 1 June 2019.
come together.                                                                           Countries with competitive energy policies will
                                                                                         increasingly become more attractive for miners, unless
Change the hearts and minds of                                                           we see breakthroughs that change the energy
the people, challenge them to think                                                      consumption of heavy processes, such as
differently and then the rest will flow.                                                 electrowinning and comminution. Comminution, in
                                                                                         particular, will grow as a proportion of mining energy
If you go and employ the right people
                                                                                         costs for certain commodities.
to be able to do this, then we can
change down to the business.

14
   “These Massive Renewable Energy Projects Are Powering Chilean Mines,” Bloomberg Businessweek,
https://www.bloomberg.com/news/features/2018-08-07/these-massive-renewable-energy-projects-are-powering-chilean-mines, accessed 4 April 2019.

14 | Will electrification spark the next wave of mining innovation?
Prepare now   Consider a world where:                           while meeting environmental and social
                                                                expectations. The integration of
to mine       • The supply of energy to mining sites            conventional and renewable energy is
tomorrow’s      goes far further than fuel mix.
                                                                critical to ensure reliable and safe power
deposits      • The IoT forms part of site design,              for the mine. The mining sector is not
                sending data on energy usage and                only calling for technical integration but
                production schedules to central or area         also for commercial integration between
                processors.                                     conventional and renewable energy, with
              • AI identifies patterns in usage,                an eagerness to retain a single point of
                intensity, frequency, or mixture of staff       accountability for power. In the event of
                or assets.                                      power outage, the manager will want one
              • Power supply is based on renewables             point of contact, rather than separate
                and battery storage. Conventional               points of contact for conventional and
                power is directed only to the parts of          renewable energy.
                the site that require it, leaving batteries
                to charge in other areas or excess              With the costs of wind and solar
                power to be sent back to the grid               generation and energy storage falling so
                                                                rapidly, managers may be tempted to hold
              Integrated, linked, thinking and                  off for a further tender cycle before
              responsive systems will bring the new             adopting renewable energy. A balance
              technologies that are transforming the            may be achieved by proceeding with a
              power grids of today into the mining sites        level of renewable capacity now and
              of tomorrow – thereby converging real             having the flexibility in power contracts to
              estate, mining, automotive, technology            incrementally increase the renewable
              and utilities through the lens of the             portion during the contract term.
              employee, the operator and the
              shareholder. Precision mining with                Above all, miners need to remain
              small-scale automated equipment could             competitive in terms of productivity,
              make small narrow-vein orebodies                  reduced operational risks and improved
              economically viable. The minimum-                 mineral recovery rates and recover metals
              efficient mine scale could fall dramatically.     and minerals of higher quality. As
                                                                deposits are increasingly becoming deep,
              Electrification represents a viable channel       remote and difficult to access, new
              for the mining sector to increasingly             innovative processes are required —
              adopt or develop new technologies, and            yesterday’s expertise may not be able to
              processes to explore mineral resources,           mine tomorrow’s deposits.

                                                 Will electrification spark the next wave of mining innovation? |   15
How EY’s Global Mining & Metals Network can                               EY | Assurance | Tax | Transactions | Advisory
help your business                                                        About EY
                                                                          EY is a global leader in assurance, tax, transaction and advisory
The sector is returning to growth, but mining and metals (M&M)            services. The insights and quality services we deliver help build trust
companies face a transformed competitive and operating                    and confidence in the capital markets and in economies the world
landscape. The need to improve shareholder returns will drive bold        over. We develop outstanding leaders who team to deliver on our
strategies to accelerate productivity, improve margins and better         promises to all of our stakeholders. In so doing, we play a critical role
allocate capital to achieve long-term growth. Digital innovation          in building a better working world for our people, for our clients and
will be a key enabler but the industry must overcome a poor track         for our communities.
record of technology implementations. If M&M companies are to
                                                                          EY refers to the global organization, and may refer to one or more, of
survive and thrive in a new energy world, they must embrace digital       the member firms of Ernst & Young Global Limited, each of which is
to optimize productivity from market to mine.                             a separate legal entity. Ernst & Young Global Limited, a UK company
EY takes a whole-of-value-chain approach to support each client to        limited by guarantee, does not provide services to clients. Information
help seize the potential of digital to fast-track productivity, balance   about how EY collects and uses personal data and a description of the
                                                                          rights individuals have under data protection legislation are available
portfolios and set a clear road map for their new energy future.
                                                                          via ey.com/privacy. For more information about our organization,
                                                                          please visit ey.com.
Area contacts
                                                                          © 2019 EYGM Limited.
EY Global Mining &                     India                              All Rights Reserved.
Metals Leader                          Anjani Agrawal
                                                                          EYG no. 003211-19Gbl
Paul Mitchell                          +91 22 6192 0150
+61 2 9248 5110                        anjani.agrawal@in.ey.com           BMC Agency
paul.mitchell@au.ey.com                                                   GA 1012053
                                       Nordics
                                                                          ED None
Africa                                 Lasse Laurio
Wickus Botha                           +35 8 405 616 140                             In line with EY’s commitment to minimize its impact on the environment, this
+27 11 772 3386                        lasse.laurio@fi.ey.com                        document has been printed on paper with a high recycled content.
wickus.botha@za.ey.com
                                       Oceania                            This material has been prepared for general informational purposes only and is not intended to
                                                                          be relied upon as accounting, tax or other professional advice. Please refer to your advisors for
Brazil                                 Scott Grimley                      specific advice.
Afonso Sartorio                        +61 8 9429 2409
                                                                          The views of third parties set out in this Publication are not necessarily the views of the global
+55 21 3263 7423                       scott.grimley@au.ey.com            EY organization or its member firms. Moreover, they should be seen in the context of the time
afonso.sartorio@br.ey.com                                                 they were made.
                                       United Kingdom & Ireland
Canada                                 Lee Downham                        ey.com/miningmetals
Jeff Swinoga                           +44 20 7951 2178
+1 416 9437 181                        ldownham@uk.ey.com
Jeff.Swinoga@ca.ey.com
                                       United States
Chile                                  Bob Stall
Eduardo Valente                        +1 404 817 5474
+56 2 916 2997                         robert.stall@ey.com
Eduardo.Valente@cl.ey.com
China and Mongolia
                                       Service line contacts
Libby Zhong                            EY Global Advisory Leader
+86 10 58153541                        Paul Mitchell
Libby.Zhong@cn.ey.com                  +61 2 9248 5110
                                       paul.mitchell@au.ey.com
Commonwealth of
Independent States                     EY Global IFRS Leader
Boris Yatsenko                         Tracey Waring
+7 495 755 98 60                       +61 3 9288 8638
boris.yatsenko@ru.ey.com               tracey.waring@au.ey.com
France, Luxembourg,                    EY Global Tax Leader
Maghreb, MENA,                         Andrew van Dinter
Francophone Sub-Saharian               +61 3 8650 7589
Africa                                 andrew.van.dinter@au.ey.com
Christian Mion
                                       EY Global Transactions
+33 1 46 93 65 47
                                       Leader
christian.mion@fr.ey.com
                                       Lee Downham
Japan                                  +44 20 7951 2178
Andrew Cowell                          ldownham@uk.ey.com
+81 80 2276 4048
andrew.cowell@jp.ey.com
You can also read