The integration of sensors and IoT technology is enhancing environmental monitoring and performance in mining. Credit: Igor Borisenko / Getty Images

Internet of Things, or IoT, describes the use of connected sensors and actuators to control and monitor the environment, the things that move within it, and the people that act within it. These connected devices serve a range of industrial applications, from inventory management to automated equipment inspections via the use of robots.

Mining, as an industry, faces a range of challenges in the immediate future. Declining ore grades force mining companies to look further and further away from civilisation for mineral deposits, all while digging deeper to retain levels of output. This effect is twofold, as mining companies’ productivity dips while employees must go further away for job opportunities. Mining also has a mixed reputation when it comes to the environment, as it is both an extractive industry, requiring intense regulation, but also one that produces critical minerals necessary for the energy transition. Additionally, mining remains an incredibly unsafe profession. According to research from Spain, the industry is 14 times more unsafe than other sectors on average.

All of these factors have contributed to a significant skills shortage within the industry. According to a 2022 McKinsey survey, 86% of mining executives struggle to recruit and retain skilled workers, with the sector facing a potential deficit of 8,400 workers by 2026 in Australia.

IoT devices have the potential to enhance safety, boost productivity, reduce expenses, uncover new resource deposits, and improve compliance with environmental, social, and governance (ESG) standards, thereby addressing some of the primary concerns of mining industry executives. Furthermore, deploying automation technologies relies on IoT sensors that aggregate large quantities of data. While the global adoption rate of automation technologies such as autonomous haulage and equipment remains modest, it is projected that by 2030, half of the mining operations in Australia will be automated, as reported by the Commonwealth Scientific and Industrial Research Organisation. This shift is anticipated to mitigate Australia's impending skills shortage by reducing the number of staff in hazardous areas by 75%.

Integrating IoT sensors and connected devices is essential to confront the extensive challenges the mining industry is expected to encounter. According to a GlobalData ICT spending forecast for the mining sector, IoT spending from mining companies is expected to increase from $5.8bn in 2025 to $8.2bn in 2027, with a compound annual growth rate of 17.3% between 2022 and 2027.

The integration of sensors and IoT technology is enhancing environmental monitoring and performance in mining. These advanced systems are particularly effective in tracking tailings - residual materials from ore processing - by utilising IoT sensor networks to oversee their containment in synthetic ponds secured by tailings dams. This dual-purpose structure not only prevents the escape of tailings but also facilitates water recycling for processing, safeguarding local biodiversity, and monitoring emissions. For instance, Rio Tinto has begun disclosing detailed water usage data across its global operations while Teck Resources has harnessed AI to optimise water treatment processes, achieving significant annual savings.

The deployment of IoT sensors around tailings dams allows for real-time surveillance of water contaminants and structural integrity, enabling swift responses to potential issues that traditional manual methods might miss. Additionally, companies such as VROC are leveraging AI to predict future dam conditions, enhancing operational planning. Beyond tailings management, sensors are also employed to measure greenhouse gas emissions, as demonstrated by Cognizant's collaboration with Orica to develop a digital platform for monitoring emissions reductions. Furthermore, satellite IoT technology is streamlining the collection of ESG data, providing real-time insights into resource consumption and pollution levels, even in remote areas. A recent Viasat study revealed that 86% of mining companies view satellite-enabled IoT solutions as essential for improving sustainability, highlighting the industry's commitment to enhancing governance and transparency through advanced technological solutions.

Mining companies are increasingly prioritising safety through the integration of wearable technology, which plays a crucial role in mitigating risks associated with the industry. These wearables, which include smart helmets, watches, badges, jackets, and body suits, are equipped with sensors that monitor various health metrics, providing real-time data that can significantly enhance safety protocols.  
 
One of the most pressing concerns in mining is fatigue, a leading cause of workplace accidents. Traditional self-reporting methods often fall short, but wearables that directly measure fatigue levels can alert miners and operators when it's time to take necessary breaks. Additionally, the extreme conditions of mining can disrupt the body's thermal regulation, leading to unpredictable vital signs. Wearable technology can continuously monitor these vitals, allowing for immediate intervention in emergencies and ensuring that all personnel are promptly notified if a health crisis arises. Furthermore, these devices can include gyroscopes to detect falls and external sensors to prevent collisions, while also serving as asset trackers to keep tabs on employee locations. For instance, Beacon Trax's sensors can warn workers of danger zones and provide updates during evacuations.  
 
Augmented and virtual reality glasses enhance training by simulating underground conditions, enabling safe practice without risk. The use of IoT sensors extends beyond wearables; autonomous haulage systems equipped with collision avoidance technology have significantly reduced accidents, with Caterpillar's Cat MineStar Command reportedly cutting mine site accidents by 50%. Drones also contribute to safety by inspecting deep shafts, ensuring staff are clear before blasting, and monitoring air quality to mitigate health risks from airborne pollutants. By employing real-time monitoring systems for particulate matter and predictive maintenance for equipment, mining companies can further reduce exposure to hazards and enhance overall safety on-site. 

Mining operations often face significant downtime due to various factors, including equipment failures, maintenance requirements, safety inspections, and adverse environmental conditions. This inactivity not only leads to financial losses but also disrupts production schedules. For instance, a recent incident at Impala’s shaft resulted in a staggering 20% revenue loss and a three-month operational halt due to unplanned downtime caused by equipment breakdowns and urgent safety concerns.

To combat these challenges, the integration of IoT technology is a game-changer. IoT enables predictive maintenance, allowing for real-time monitoring of equipment health through remote sensors, which helps identify potential issues before they escalate. Companies such as Anglo American and Vale have reported remarkable reductions in unplanned downtime - up to 75% - and significant productivity increases thanks to these advancements. Furthermore, IoT facilitates the automation of mining processes, enabling remote control of equipment and enhancing operational efficiency. For example, autonomous trucks powered by IoT technology can operate continuously, eliminating human error and improving productivity by 15% to 30%.