As domestic mines modernise and mechanise, certain systems – such as ventilation-on-demand (VoD) technologies and battery-electric vehicles (BEVs) – are likely to see the fastest adoption in deep-level mines, says equipment manufacturer cluster Mining Equipment Manufacturers of South Africa (Memsa) marketing and communications officer Sue Breckenridge.

Memsa’s sentiment is shared by local mining original-equipment manufacturers (OEMs), with VoD and BEV technologies set to develop even faster than those of fully autonomous systems or digital twins.

“Deep-level mines in South Africa face lofty cooling and ventilation costs, often representing one of the largest energy expenditures,” she adds, further noting that, for deep gold and platinum mines operating several kilometres underground, reducing ventilation demand directly lowers operating costs, hence the accelerated adoption of VoD.

VoD enables mine operators to scale ventilation either as and when it is required for certain areas, consequently effecting energy savings, or only when personnel or internal combustion engine vehicles are present there.

VoD systems are increasingly integrated with technologically advanced digital control platforms that optimise ventilation and cooling systems in real time.

Breckenridge adds that BEV demand and use are also gaining traction because such vehicles reduce diesel emissions underground, which, in turn, lowers ventilation requirements and improves worker safety.

“Electrification of underground equipment is seen as a critical step towards more sustainable and cost-efficient mining operations,” she says.

As a result of increased demand, South African OEMs are increasingly designing battery-electric load-haul-dump machines and support vehicles suited to narrow-reef and deep-level mining.

Memsa expects that autonomous equipment and digital twins will follow but are likely to scale more gradually in deep-level mines because of operational complexity.

“Industry projections suggest 30% to 40% of mining equipment in Africa could become autonomous by 2040, indicating steady but staged adoption,” adds Breckenridge.

Memsa Model

Memsa members consistently face several key barriers when trialling new deep-level mining technologies, including capital costs, the need for upgraded infrastructure and power, as well as energy uncertainty and escalating electricity prices.

Many deep-level mines operate on tight margins and ageing infrastructure, making it difficult to justify large upfront investments in electrification products, automation systems or digital platforms.

“However, this is being addressed by local manufacturers who are developing modular systems and retrofit solutions that can integrate with existing equipment fleets,” adds Breckenridge.

In terms of South Africa’s grid electricity constraints, many mines are cautious about electrification strategies. If they were to embark on the electrification of equipment, they would most likely lean more towards combining BEV adoption with renewable-power and microgrid solutions to stabilise and guarantee their supply.

OEMs, in turn, are responding with the design of fast-charging and trolley-assist electrification systems, and hybrid electric equipment, in addition to developing energy efficient drivetrain technologies.

“While fully autonomous ultradeep mines are still emerging, several pilot projects demonstrate the trajectory of technology deployment,” notes Breckenridge.

Battery-electric machinery is increasingly being tested across African mining operations, the pilot projects of which are helping OEMs to adapt equipment to the adverse mining conditions.

Further, Breckenridge says digital twin platforms are being used to simulate mining operations, optimise processes and test system changes before implementation, consequently helping to reduce risk and improve productivity.

“Industry data suggests digital twin technologies are already being piloted or implemented across a significant share of mining operations globally, with adoption expected to deepen and expand across entire value chains over the next decade,” she concludes.