From the moment we wake up to the time we drift off to sleep, copper is tightly woven into the fabric of our life. It’s in the wires powering electronic devices, the pipes carrying water to our home, and the batteries powering our electric vehicles.
Not only is copper the bread and butter of our daily life, but is also indispensable to all energy transition plans. Each type of electric vehicle (EV) uses considerably more copper than traditional vehicles with internal combustion engines. According to a study from International Copper Association, EVs, including hybrid EVs, will account for 56 % of copper demand from wire harness in 2032, an increase from 20% in 2022.
But how can we meet this growing demand for copper in a sustainable way, especially in a time marked by labour shortages, geopolitical instability, and climate change? A possible solution lies above the arctic circle in the north of Sweden, at Boliden Mineral AB (below as Boliden)’s Aitik mine.
Four Facts about Boliden Aitik
- Situated in the wilderness of Sweden, Boliden Aitik is Europe’s largest open-pit copper mine.
- Approximately 40 million tonnes of ore is mined in Aitik around the clock from chalcopyrite that contains copper, gold and silver. The open pit is 3 km long, 1.1 km wide and 450 meters deep – so far.
- The work in Aitik is done by some of the biggest, cleanest and technologically most advanced machines in the world, making it one of the safest and most productive mines globally.
- These machines are operated by nearly as many women as men, which makes Aitik one of the most gender-equal mines in the world.
Caution! Entering the Autonomous Operation Zone
Since 2024, Aitik is expanding its operations with the development of a new satellite mine, Liikavaara, located 3 km away from the main site. Building on its tradition of being the test bed for innovations and new technologies, Boliden is implementing Komatsu's FrontRunner autonomous haulage system (AHS) on the Liikavaara mine. This makes Aitik the first mine in Europe and the Arctic environment to benefit from this advanced way of working.
“Our primary goal to achieve with the AHS system is to increase the safety level,” explains Tomas Eriksson-Ek, General Manager at Aitik. “We want to eliminate risks like slips, or large rocks accidentally falling causing potential injuries to operators. There will also be in general fewer” staff working physically in the production area.”
As the haulage trucks are autonomous, there is much less uncertainty involved in the entire operation. This also leads to higher productivity because machines can be used more often, with no more shift changes or operator breaks.
Moreover, AHS also ensures that the machines are utilised in an optimal way, and this tends to improve their longevity, which in the long term lowers cost. The fuel economy is also optimised by operating within the design parameters.
Another aspect is the accuracy in the operation. AHS system helps place materials in their exact locations, reducing the risk of mix-ups and minimising the need for rework.
Rikard Mäki, Head of Electrification & Automation at Boliden, says: “In the long run we expect that the AHS system will further increase productivity and minimise unscheduled downtime through more accurate component life prediction since the trucks are consistently driven to their optimum operating characteristics.”
Automating Processes
In fact, when we talk about AHS, it’s much more than taking operators out of their seats – it’s about automating and optimising work process.
The successful deployment of the autonomous system always starts with an effective and productive mine plan. It outlines production targets, equipment locations and crusher demands, etc., and this forms the foundation for all of the automation. The more effective the mine plan is, the more powerful the automation can be.
The next step involves a fleet management system, such as the Komatsu DISPATCH, that effectively manages and analyses mine layout and production requirements. This information is then transmitted to the AHS supervisory system, that’s where autonomous technology comes into play. The supervisory system, or in other words, AHS will then communicates the assignments to the truck navigation, quickly and effectively.
“The successful implementation of automation depends on organiszational development, leadership development, and empowering the workforce,” says Rikard.
“Central EMV 51, in passing at the gate.”
At Boliden, the deployment of the autonomous system has led to the creation of new roles that require specialised skills. This process of change management is accompanied by a team of experts from Komatsu and the local distributor Hesselberg Maskin AB (below as Hesselberg).
One of such roles is the central controller, who manages the flow of the entire operation from the central control room, making sure things are running the way they are supposed to. They use the FrontRunner software to set speed restrictions, supervising road conditions, dumping courses, or any other variables for the autonomous trucks, and they intervene in case of problems, such as a truck breakdown or an obstacle in the path. Today, trainers from Hesselberg are working closely with central controllers from Boliden in the control room, making sure that everything runs safely.
Former truck driver Pontus Wallgren, now a central controller, tells us that his working condition is greatly improved: "I used to spend countless hours in a truck, but now my job is much more ergonomic. I can now interact with machines remotely, in a more comfortable and efficient way."
While the central controller oversees the operation from a bird's-eye view, the pit patroller acts as the eyes and ears on the ground. If a truck stops because of an obstacle for example, they can find out easily what it is, remove it, and then restart the truck from their location, or communicate with the central control room to restart the operations.
“With the autonomous trucks, I actually feel safer, because the trucks are following the precise routes and there is no risks of driver being distracted or feeling fatigue,” says Erika Johansson, a pit patroller at Boliden Aitik.
The paradigm shift from manual to autonomous mining necessitates a robust training program to upskill the personnel. Specialised trainers from Komatsu and Hesselberg are responsible for equipping personnel with the necessary knowledge and skills. The trainings have been carried out in the form of classrooms as well as with simulators. “We have a training team of 13 to 14 trainers who have been on site throughout the project,” explains Rikard. Until now, over 100 operators have been trained in Aitik to support the autonomous operation, covering traditional roles like shovel, dozer, and grader operators, as well as new roles specifically designed for the autonomous system.
The transition to AHS requires a collaborative effort between Boliden, Hesselberg and Komatsu. By creating value together, we can unlock the full potential of automation and ensure a safe, clean and productive mine site to tackle the challenges of the present and future. Today, all production in the Liikavaara pit is managed by the Komatsu Frontrunner AHS system 24/7. The fleet has moved approximately 9 million tons of material, with 5 million tons originating from Liikavaara.
