Proof of Concept: The Success of Drone Technology in Mining

In mining, drones have shown significant potential to improve operations and enhance safety. But, how effective are drones in a mining context? Before making significant investments, many mining companies initiate a Proof of Concept (PoC) to test how drones could benefit their specific operations. In this post, we’ll explore some successful PoC case studies around drone technology in mining.

What Is a Proof of Concept (PoC) in Mining?

A Proof of Concept (PoC) is a preliminary test that evaluates the feasibility and potential impact of a new technology in a real-world setting. In mining, a PoC for drones involves deploying them in a controlled environment or on a smaller scale to measure effectiveness before committing to full-scale integration. PoCs are particularly important in mining due to the industry’s complex environments and demanding operational requirements. A drone PoC typically focuses on specific tasks—such as mapping, inspection, or volumetric analysis—that drones can perform more safely, accurately, or efficiently than traditional methods.

Successful Drone PoC Case Studies in Mining:

20+ ways to use the Hovermap in Underground mining

Hovermap, a LiDAR-based SLAM (Simultaneous Localization and Mapping) system, offers extensive applications for data capture in underground mining, enabling safer and more efficient operations. When mounted on a drone, it allows autonomous flight in GPS-denied environments, capturing high-quality data from previously inaccessible areas. This enhances decision-making by providing accurate, real-time 3D maps of underground voids and structures, all while keeping personnel out of hazardous areas.

Key Applications:

1. Informed Decision-Making: Access to detailed data from inaccessible areas like stopes and ore passes supports data-driven planning and production optimization.
2. Improved Safety: Minimizes personnel exposure to hazards by enabling remote data capture.
3. Cost Savings: Reduces the need for expensive equipment and consultancy services by offering a versatile and user-friendly solution.
4. Development Monitoring: Scans heading development, tracks over-break, and calculates cut volumes post-blasting.
5. Structural and Ground Support Analysis: High-resolution scans support structural recognition and assessment of ground support conditions.
6. Convergence Monitoring: Tracks ground support changes over time, aiding in rehabilitation planning.
7. Post-Blast Analysis: Measures stope volumes and evaluates blast performance, supporting more efficient resource extraction.
8. Vent and Orepass Inspections: Inspects critical infrastructure to ensure safe operation and detect stress-induced damage.
9. Geological Feature Identification: Captures detailed rock mass data, aiding geotechnical planning.
10. Decommissioned Infrastructure Scanning: Inspects old or abandoned structures to assess stability and plan for future use.

Stockpile Management

One key area where drones have proven valuable is stockpile management. Accurate volume calculations are essential for inventory tracking and financial planning in mining operations. Traditional methods, often reliant on ground surveyors and manual measurements, can be time-consuming and costly. In PoC trials, drones equipped with LiDAR and photogrammetry sensors have demonstrated the ability to map stockpiles quickly and with high precision. By capturing aerial data, drones streamline the process, delivering faster and more accurate measurements.

DJI Enterprise drones, combined with DJI Terra software, offer an efficient and accurate solution for stockpile volume measurement across industries like construction, mining, and agriculture. This method addresses common issues in traditional inventory tracking, such as safety risks and time-consuming processes, by allowing frequent, precise calculations of material volumes.

Workflow for Drone-Based Stockpile Measurement:

1. Select the Right Hardware: High-resolution cameras (such as on the DJI Mavic 3 Enterprise or Matrice 350 RTK with Zenmuse P1) ensure image clarity and data accuracy. RTK (Real-Time Kinematic) integration enhances precision, especially in frequently updated sites.

2. Mission Planning: Using DJI Pilot 2, users can set up automated mapping missions. Specific settings, such as flight altitude (recommended 250 feet AGL) and overlap settings (70% side, 80% front), are adjusted to capture clear, accurate stockpile data.

3. Data Processing in DJI Terra: Post-flight, images are processed in DJI Terra to create 2D maps and 3D models. Ground Control Points (GCPs) or checkpoints are optional but improve accuracy. DJI Terra allows volume measurements by defining base planes (mean plane or lowest point) for Cut and Fill calculations.

4. Data Export and Analysis: The final data can be exported to other software like Trimble Business Center, DroneDeploy, or Propeller Aero for further analysis, tracking changes over time, and calculating costs or material densities.

Underground Mapping (SLAM)

Drones equipped with Simultaneous Localization and Mapping (SLAM) technology have shown considerable promise in underground mapping, a task that is inherently risky for human workers. SLAM-enabled drones can autonomously navigate dark and confined environments, generating 3D maps in real-time. This capability has proven invaluable for mining operations that need regular updates on tunnel conditions and structural stability. PoC projects in this area have shown that drones equipped with SLAM can significantly reduce time and risk in underground mapping compared to manual methods.

Project Overview Byrnecut, a global mining contractor, partnered with Emesent to implement the Hovermap LHD system, aiming to enhance safety and productivity in Load-Haul-Dump (LHD) operations. This innovative solution addresses challenges like low visibility and hazard detection in underground mines, where traditional 2D cameras and Cavity Monitoring Systems (CMS) fall short.

Key Achievements

• Near real-time stope hazard and volume assessments
• 24/7 scanning capability for crews
• Increased stope turnover
• Positive ROI within 2–3 hours of downtime prevention

Challenges In underground mining, LHDs face visibility and safety issues, especially in detecting loose rocks or hazardous rill angles, increasing the risk of equipment damage and operational delays. Traditional CMS scanning requires trained surveyors and is typically limited to day shifts, slowing down decision-making and productivity.

Solution Hovermap LHD, using SLAM-based LiDAR technology, provides a 300-meter range and 360-degree view, allowing remote operators to view high-resolution 3D point clouds of the stope in real time, even in low-light conditions. The system mounts easily on LHDs and streams data to operators, facilitating continuous monitoring and safe, efficient operations. Its user-friendly design requires no specialist training, enabling non-surveyors to conduct scans anytime, improving equipment planning and allocation.

Results

• Significant reduction in scanning time: Areas that previously took two days to scan are now captured in 10 minutes.
• Reduced geotechnical risk: The system prevents LHD entrapment and equipment damage, providing ROI within a few hours.
• Increased productivity: The ability to perform rapid assessments has accelerated decision-making, enabling quick equipment relocation and increased stope turnover.

Results from These PoCs

The success of these PoCs has yielded several measurable benefits, leading to widespread adoption of drones in mining. Here are some standout results:

• Accuracy: Drone surveys often achieve centimeter-level precision, allowing mining companies to track resources more reliably.
• Cost Savings: By reducing the need for manual surveys, drones cut costs associated with labor and equipment. PoCs have shown that companies can save up to 50% on surveying expenses by using drones.
• Operational Efficiency: Drones complete tasks faster than traditional methods. For example, stockpile management that might take several days with manual measurements can often be done within hours with a drone, improving overall productivity.
• Safety Improvements: By removing human workers from hazardous areas, drones significantly improve safety, a critical factor in mining environments where risks are high.

These results underscore the transformative potential of drones in mining, making a strong case for running a PoC before adopting them on a larger scale.

How to Start a Proof of Concept for Your Mining Operation

If you’re considering a PoC for drone technology in your mining operation, here’s how to get started with Candrone’s guidance:

1. Define Your Objectives: Identify specific areas where you believe drones could improve efficiency, safety, or accuracy.
2. Choose the Right Drone and Sensors: Based on your objectives, select the appropriate drone model and sensor types, such as LiDAR, photogrammetry, or SLAM.
3. Set Up Data Collection Protocols: Establish clear protocols for data collection, processing, and analysis to ensure consistency and accuracy.
4. Conduct the PoC: Deploy the drones under controlled conditions, focusing on gathering data relevant to your identified objectives.
5. Analyze and Evaluate: Once the PoC is complete, assess the results. Did the drone achieve the desired accuracy? Did it lead to cost or time savings? Was safety improved?
6. Plan for Scale: If the PoC is successful, work with Candrone to plan a larger-scale implementation based on the insights gained.

The growing success of drone PoCs in mining demonstrates how effective these technologies can be, but a successful PoC is essential before full-scale adoption. By running a PoC, mining companies can assess the benefits drones bring to their specific operations, gaining confidence in the accuracy, cost savings, and efficiency improvements they deliver. With Candrone’s expertise, you can embark on a tailored PoC that unlocks the full potential of drones in your mining operations, ensuring a safer and more efficient future in the industry.