Reimagining Material Movement in Underground Mining
A MICA mining operator is undertaking a strategic review of how material is hauled, particularly in underground operations, as current methods (primarily truck-based) are increasingly seen as suboptimal in terms of cost, flexibility, and long-term scalability. This initiative aims to identify, evaluate, and eventually pilot new material movement technologies that reduce operational cost, improve energy efficiency, and prepare for future high-tonnage demands (e.g., 5,000+ tonnes/day by 2030).
The mine operator is looking for a solution to transfer ore from underground to the surface and/or to the mill, and are open to solutions to reduce OPEX and GHG emissions.
Core Challenges
Status Quo Limitations
- Overreliance on Trucks: Mobile haulage is the default, even when better alternatives may exist. This stems from availability, not operational optimization.
- Legacy Practices: Equipment is often transferred from existing projects to new ones to reduce CapEx, leading to long-term inefficiencies.
- High Operating Costs: Trucks introduce significant OPEX (fuel, maintenance, labor) and have growing logistical limitations underground.
Methodology Constraints
- Optimization of existing truck fleets (automation) is being explored but may not address the fundamental need for alternative haulage methodologies.
- There’s a desire to break the reflexive use of trucks and rethink the system from first principles.
Scalability & Infrastructure Pain Points
- Truck haulage does not scale efficiently for emerging underground projects requiring 5,000+ tonnes/day.
- Existing infrastructure presents space and power limitations, making high-density trucking less viable.
Opportunity & Vision
The goal is to use the right tool for the right task. The operator is seeking:
- Fit-for-purpose material movement systems: for repetitive, fixed-path haulage.
- A hybrid approach: flexible near-face mobility (LHDs or autonomous scoops) combined with fixed systems (conveyors, pumps).
- Open innovation pathways: collaboration with emerging vendors or cross-industry providers to find scalable, efficient, and future-ready alternatives.
Strategic Benefits
- Operational Efficiency: Assign the right technology to the right job, flexibility where needed, efficiency where repeatable.
- Decarbonization Pathway: Reduce diesel reliance and environmental impact.
- Future-Readiness: Align infrastructure with anticipated project needs and production rates.
- Ecosystem Positioning: Establish the company as a forward-thinking partner for mining innovation.
Desired Technology Profile
- TRL Level: Preference for TRL 5+, but open to promising earlier-stage solutions.
- Capacity Potential: Should be scalable to 5,000+ tonnes/day.
- Operational Model: Hybrid models preferred, flexible at the face, fixed for long-distance haulage.
- Cost Objectives: Reduce long-term OPEX.
- Mine Types: Focus on underground; open to dual application with open-pit sites.
- Integration Flexibility: Minimal infrastructure constraints preferred; adaptable to various sites.
Note: The organization is not yet in a detailed cost modeling phase. The current focus is on identifying available technologies and future potential.
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