Celebrating a century in mining, Tata Steel’s Noamundi Mine in Jharkhand also marks its transition from traditional mining practices to AI-driven technologies, ensuring efficiency, safety and sustainability.
In an exclusive interview with AIM, DB Sundara Ramam, vice president (raw materials), Tata Steel, said, “Noamundi Mine utilises AI models to analyse geological data, enabling precise target mining and resource optimisation.”
According to him, this data-driven approach helps identify areas with high mineral concentration, minimising waste and maximising extraction efficiency. “One of the significant risks of mining operations is handling large boulders in the crusher feed,” Ramam said.
Traditionally, this required manual intervention and was a potential safety hazard. However, thanks to AI, this practice has changed now. “AI-based imaging techniques are employed to detect boulders on dumpers and prevent jams in the crushers,” said Ramam.
In order to improve plant reliability and minimise downtime, the mine implemented AI models under its maintenance technology roadmap. “These predict potential equipment failures, enabling proactive maintenance and reducing unplanned shutdowns,” adds Ramam.
Upbeat about the implementation of AI at the mine, Ramam said that it has resulted in several benefits, such as increased efficiency, enhanced safety, reduced costs, and improved sustainability, by optimising resource extraction and reducing waste.
“Noamundi Mine’s embracing of AI demonstrates its commitment to innovation and continuous improvement. By leveraging the power of AI, the mine is paving the way for a more efficient, safe, and sustainable future for its mining operations,” says Ramam.
Machine Learning and Mining
Ramam also spoke about how the original equipment manufacturers (OEMs) have set specific vibration thresholds for the machines, which are programmed into the sensors.
He explained that though it is all part of machine learning, there is also a layer of human input. Drawing from experience and upon consultations with OEMs, they have added specific conditions and data points to fine-tune the system’s response.
The industry is moving towards digital mines, resulting in connectivity between equipment systems in real time, and enabling real-time analysis and decision making.
There are numerous use cases of IoT and analytics solutions across industries such as mining, power generation, ports, construction sites and irrigation. Real-time solutions ensure safety, reliability and compliance with the environmental standards set by the statutory and regulatory bodies.
Real-time IoT and analytics solutions provide real-time monitoring, and extrapolation of dust and moisture. Machine learning also plays a significant role in safety monitoring in terms of detecting blindspots. He states ,“So every week on mobile I get a message saying that, in the last one week, these are the areas of blind spots ”
Interestingly, Ramam said that Noamundi Mine will soon be using GenAI tools like ChatGPT to streamline various processes further. Currently, multiple teams are involved in monitoring and interpreting data, but with tools like ChatGPT, a single person would be able to manage these operations across multiple sites.
Ramam illustrates how Tata Steel’s mining practices have evolved with advancing technology. “Until a few years ago, we would carry out manual surveys. Today, we use drones across all locations.” Drones can survey a large area in just about two hours, providing detailed insights, including water levels, slime dam conditions, stock levels and more.
Is AI Replacing Humans in Tata’s Mines
“We’re planning to reduce human involvement, but not simply because others are doing it that way,” says Ramam. “Our social licence to operate relies on community acceptance, and we don’t want to impose drastic changes that disrupt the community.”
He explained the significant strides they are taking to improve safety and risk management by using AI and machine learning across all operations. As a result, they can make data-driven decisions to manage risks and ensure safety more effectively.
Ramam added that currently only about three or four mines operated with these systems in place. They, however, plan to extend this to all their sites in the near future.
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