The high-altitude copper mining operation situated on a plateau at 5,600 meters, known for being the world's highest and possessing the largest copper metal reserves in Asia. This environment presents severe challenges including extreme cold, temperatures plummeting to -40°C, constant dust and snow, and extremely low oxygen levels. These harsh conditions have led to significant difficulties in labor recruitment and retention. In 2023, the client sought our tele+AI solutions to enhance operational safety, efficiency and employee satisfaction.
Challenges
Before implementing our solutions, the client faced several critical challenges:
- Extreme Environment: The mine's high-altitude location resulted in low oxygen and air pressure, making it hard for workers to breathe and perform tasks effectively.
- Harsh Working Conditions: Temperatures consistently below zero, along with frequent dust and snow, exacerbated physical discomfort and risk for the workers.
- Labor Shortage: The demanding environment led to a high churn rate of 40%, with the mine often able to recruit only one operator per year despite needing four for optimal operations.
- Safety Concerns: The life-threatening conditions necessitated extensive safety measures, including emergency supplies and collaborative travel to prevent altitude sickness-related accidents.
Solution
Our tele+AI solutions, retrofitted a TZ WK-35C Electric Shovel equipped with 5G network capabilities and advanced AI functions, addressed these challenges effectively. Key features included:
- Auto-Loading: Enhanced efficiency by allowing full truck loads within four minutes.
- Pedestrian Detection and Anti-Collision Warning: Improved safety by reducing the risk of accidents in the mining area.
- High-Pressure Flameout/Shutdown: Added a critical safety layer to prevent equipment malfunctions in the extreme cold.
Implementation
The implementation process involved installing a remote intelligent control system on the TZ WK-35C Electric Shovel, which operates continuously at over 5,400 meters. Our team collaborated closely with the client to ensure seamless integration of the 5G network and AI functionalities. Customizations were made to adapt the shovel's operations to the harsh environment, emphasizing the need for durability and reliability in extreme conditions. Training was provided to ensure that operators could effectively manage the remote control system, thus eliminating the need for their physical presence in hazardous zones.
Results
The outcomes of our tele+AI solutions were significant:
- Increased Efficiency: Operators could complete a full truck load within four minutes, markedly improving operational productivity.
- Enhanced Safety: The remote control system ensured operators no longer had to endure the extreme cold or hazardous conditions, drastically reducing health risks and ensuring their safety.
- Improved Job Satisfaction: The ability to work remotely alleviated physical strain, leading to greater job satisfaction among operators.
- Labor Recruitment: The enhanced working conditions and safety measures made the mine more attractive to potential recruits, mitigating the labor shortage issue.
Overall, our tele+AI solutions not only improved efficiency and safety at the copper mine but also addressed the critical challenge of labor shortages by making the work environment more manageable and appealing.