Automation in Mining: Kiruna Case Study

August 11, 2021

Equipamento de perfuração de mineração em uma mina

The future of mining points to a trend towards increasingly continuous and automated processes to meet the growing global demand for mineral commodities. The implementation of automated systems has increased the productivity of mines, as well as providing safer operations, reducing operators' exposure to the daily risks of a mine. The Kiruna Mine in Sweden stands out among mines with autonomous operations, leading the way in the application of underground technologies.

Kiruna stands out in terms of autonomous and modern mining, as well as acting as a testing ground for various equipment manufacturers, such as ABB, Epiroc, Combitech and Sandvik. It is currently considered the second largest underground mine and the largest underground iron mine in the world.

In today's text, we'll cover:

Kiruna Mine
Kiruna: Automated operations
LKAB 5.0 project
Kiruna reconstruction

Kiruna, maior mina subterrânea de ferro. Fonte: NASA Earth Observatory.

Kiruna Mine

The Kiruna Mine, located within the Arctic Circle in northern Sweden, began operations in 1890 as an open-cast mine and in the mid-1950s began the transition to underground mining.The operation, which is run by the company Luossavaara-Kiirunavaara AB (LKAB), focuses on process optimisation, with automated systems and extensive application of technology.

Since its implementation, an extensive infrastructure has been set up at the site to meet production, which was around 27.5 million tonnes/year of iron ore in 2017. Today, Kiruna mines around 80% of Europe's iron ore, which corresponded to 27.1 million tonnes in 2020. Kiruna is thus considered the largest iron producer on the continent.

Production process

In addition to Kiruna, LKAB's production operations are located in Malmberget and Svappavaara. The ore is extracted from LKAB's underground mines using the SubLevel Caving (SLC) method, on a large scale, in sublevels spaced 28.5 metres apart vertically, and is currently 1,365 metres from the surface.

In this method, extraction is carried out by means of regularly spaced sublevels developed in the ore body. SLC is a highly mechanised method in which the ore is drilled, blasted, loaded and transported to underlying levels by gravity. To learn more about the SLC method, watch this video.

Método de mineração Sublevel Caving (SLC) em Kiruna ilustrado graficamente com explicações.

Transporte do minério por ferrovias, Kiruna. Fonte: LKAB.

The processing plants are located in Malmfälten, where the extracted ore is sent for comminution, concentration and pelletisation. Finally, the products are transported by rail to the ports and distributed to the various customers.

With regard to annual production at Kiruna, in 2017 around 27.5 million tonnes of ore were mined, producing 15 million tonnes of pellets. According to LKAB, 27.1 million tonnes of iron ore products were produced at its operations in 2020.

Automação na Mineração, Kiruna. Fonte: LKAB.

Automated operations

The Kiruna mine is reported to be a world leader in pioneering and innovation, especially when it comes to the use of remotely controlled equipment. With this in mind, digital systems have been developed for the various operations in the production process.

Thus, remotely controlled drilling equipment, LHDs and wagons are widely used at Kiruna. Drilling is carried out by a remote-controlled drilling unit, which is operated and monitored by operators from a control room. In addition, the injection of explosive into the holes is carried out by robots. After detonation, LHDs transport the extracted ore, supplying the wagons that operate at a level of 1,365 metres underground.

Since 2008, new methods have been developed for dynamic rock reinforcement, and important new systems for recording and analysing seismic activity have been installed. In addition, LKAB has pioneered underground wi-fi, with the largest system in the world today. As a result, wireless communication systems were developed beforehand, and today they are used for everything from mobile phone and tablet apps to driverless lorries. In short, artificial intelligence (AI), augmented reality (AR) and driverless vehicles are realities in Kiruna.

Perfuratriz Simba, do tipo long role, usada em Kiruna. Fonte: Atlas Copco Underground Mining.

Autonomous equipment in Kiruna

The demand for robust, automated equipment comes from large equipment companies such as ABB, Combitech, Epiroc and Sandivik.

ABB works mainly with electrification and the delivery of automation platforms. With this, energy-efficient systems are deployed in the electric vehicles supplied by Epiroc and Sandivik, including battery solutions and flexible electrical infrastructure. Combitech operates in the areas of mine automation and digitalisation. Among the equipment used is the Simba long hole drill and the Toro LH625iE loader from Sandivik.

The long-hole drills, called Simba, are used in Kiruna and are equipped with multiple functions, allowing them to be operated remotely in various ways. They also have sensors for angular inclination. In addition to production drilling in the highlights, Simbas are successfully used for slot drilling and some auxiliary drilling. The following video shows Simba in operation.

Watch the video

Carregadeira Elétrica, Toro LH625iE, da Sandvik. Fonte:Planta De Equipament.

It should be noted that the production of drilling machines can continue to operate without operators during shift changes, lunch breaks and night shifts. This means that control of the operation is carried out via control rooms.

Finally, we'll talk about Sandvik's largest capacity electric loader, the Toro LH625iE. The equipment has been customised to meet Kiruna's demands, including better energy efficiency, with advanced technology, the latest digital solutions and intelligent connectivity.

Watch the video below to see how Sandvik's Toro loader works.

Watch the video

Toro's operation can be carried out by operators, but the use of integrated digital solutions such as AutoMine® and OptiMine®, allows for autonomous operations, where loading and transport is carried out remotely, as well as optimising processes based on data collected in real time.

LKAB Project 5.0: The sustainable mining of the future

LKAB 5.0 is an LKAB project focused on building a new global standard for deep-sea mining. Aiming for an evolutionary change, the project's expectation is to establish a new concept of the carbon dioxide-free, digitalised and autonomous mine of the future.

The project began in June 2018, following the same precepts adopted over the years, with an even greater focus on being at the forefront of technological development. By improving the mining, processing and logistics systems, LKAB intends to design an infrastructure for the future, as the basis for a new production system at great depths. Find out more about the project.

In this way, LKAB, in partnership with ABB, Epiroc, Combitech and Sandvik, aims to develop this industrial project to achieve the goal of a sustainable mine by 2030, making operations even more technological and autonomous. Watch here ABB's video on the project.

An example of equipment designed by Epiroc is the Boomer M2, a robust, battery-powered drilling jumbo.

Cidade de Kiruna, na Suécia. Fonte: Vila de Utopia.

Rebuilding Kiruna

After more than 100 years of mining in underground galleries, Kiruna has entered a process of reconstruction. As activity progressed deeper underground, cracks appeared in the buildings and structures in the town of Kiruna, near the mine, due to the subsidence of the ground.

In 2014, the city began to relocate to a new site, about two miles to the east, and this process is expected to end in mid-2034. As a result, buildings will be moved, lifted and relocated, or dismantled and rebuilt. Find out more about the project in the video below.

Watch the video

Imagem de Satélite de Kiruna. Fonte: Google Maps.

The Kiruna mine is the town's main employer and is of great importance to the population. Currently, part of the population lives in the new town, and plans are afoot to relocate in line with the mine's activities, so that it continues to generate jobs, income and opportunities for the town. To explore the city of Kiruna further, click here or on the image below.

In a project of such importance to the city and local economy, those involved include urban planners, landscape architects, biologists, civil engineers, construction experts and contractors.

An exhibition at Stockholm's national centre for architecture and design (ArkDes) has drawn the world's attention to the city's urban relocation planning. The exhibition "Kiruna Forever" analysed this change through more than 100 works by architects, urban planners and artists. The exhibition is temporarily closed, but part of the exhibition can be explored online here.

Interested in the subject? Check out other articles on our blog!

References

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