Vale says it is to start trialling autonomous haulage at its Carajás mine in Pará, Brazil, following a successful deployment at its Brucutu iron ore mine in Minas Gerais.
The company plans to run both autonomous and manned trucks at the operation, the world’s largest open-pit iron ore mine, it said.
Completion of the autonomous testing phase is planned to June 2020, when the autonomous vehicles begin to operate. The number of autonomous vehicles will increase year by year and, depending on the test results, may reach 37 in 2024.
Combined with a staff development and training plan at Carajás, the autonomous innovation aims to increase the safety of operations, in addition to generating environmental benefits and a competitive edge, Vale said.
Two autonomous trucks are expected to start the testing phase in an isolated area of Carajás mine by the end of November, but training of the operators began in October. In addition to autonomous haulage, three autonomous drills started operating in the mine last year, Vale said.
Vale explained: “In an autonomous operation, trucks are controlled by computer systems, GPS, radar, and artificial intelligence, and monitored by operators in control rooms located miles away from the operations, providing more safety for the activity. When risks are detected, the equipment shuts down until the path is cleared. Sensors of the safety system can detect larger objects, such as large rocks and other trucks, as well as people near the roads.”
Compared with conventional transport, productivity of the autonomous operation system is higher, according to Vale. “Based on the technology market data, Vale expects to increase the useful life of equipment by 15%. Fuel consumption and maintenance costs are also estimated to be reduced by 10%, and the average speed for trucks will increase,” it said.
Autonomous operation also brings important environmental benefits. The reduced consumption of fuel by the machines results in a lower volume of CO2 and particulate matter emissions and less waste, such as parts, tyres and lubricants.
According to Antonio Padovezi, North Corridor Director for Vale, in addition to the safety factor, the use of autonomous equipment in Carajás will ensure greater sustainability for Brazilian mining. “It is another breakthrough with great economic, environmental, and social gains. It reduces employees’ exposure to risks, increases competitiveness, reduces emission of polluting gases and promotes professional training and development, following a natural trend experienced today in the market worldwide,” Padovezi said.
Implementation of the autonomous operation is combined with a staff development plan, which includes creation of a training centre in the city of Parauapebas by the supplying company. The plan is along the lines of Brucutu, where all conventional truck operators will be reassigned to other activities. At Brucutu, part of the team is managing and controlling the autonomous equipment while another part is taking on new “automation-related tasks”. Some employees have been reallocated to other areas.
Vale is deploying a digital transformation program as part of its Industry 4.0 developments.
This has allowed the company to increase productivity, operational efficiency, and safety, in addition to improving its financial performance and driving innovation, the company said.
Technological innovations developed by the company include the Internet of Things, artificial intelligence, mobile applications, robotisation, and autonomous equipment (such as trucks and drills).
The program will also support the strategic pillars presented by Vale this year – improve the company’s operational approach to safety and operational excellence as well as bring a positive impact to society, becoming a development facilitator for the areas in which it operates while promoting a safer and more sustainable industry, Vale said.