Mining may not often cross our minds, yet nearly every product we rely on originates from natural resources extracted from the Earth. Today, artificial intelligence is revolutionising the mining industry by enhancing efficiency, improving safety, and supporting sustainability.
Smarter, Safer Equipment with AI Integration
Mining operations often take place in hostile environments, where safety risks and operational inefficiencies abound. AI is increasingly being used to support or replace humans in high-risk tasks. Autonomous vehicles — including drills, loaders, and haul trucks — are now commonly employed in large-scale mining projects, enabling operations to continue with high precision in dangerous conditions.
AI also supports predictive maintenance by analysing data from sensors on heavy machinery to detect faults before breakdowns occur. This reduces costly downtime and extends the life of equipment.
A notable example is Fortescue Metals’ recent investment of $2.8 billion in a fleet of 360 autonomous battery-electric haul trucks. Guided by the company’s in-house AI navigation system, these vehicles are expected to save around 400 million litres of diesel annually, cutting Fortescue’s Scope 1 emissions by 51% and reducing haulage expenses through improved dispatch algorithms.
AI Optimises Core Mining Processes
AI technologies are also streamlining key aspects of mining operations, such as resource extraction and processing. From crushing and grinding to flotation, AI systems monitor and optimise each stage, adjusting parameters in real-time to enhance throughput, reduce energy use, and minimise waste.
Furthermore, AI is enhancing resource estimation by interpreting geological and sensor data to provide more precise information about mineral deposits. This results in more efficient mine planning and improved resource recovery. AI-driven tools are also aiding in ore grade prediction and mineral exploration by identifying patterns in seismic data and satellite imagery, helping mining firms locate and evaluate new reserves more accurately and quickly.
Boosting Mine Safety and Operational Oversight
AI plays an essential role in improving on-site safety. Systems that monitor sensors, cameras, and wearable devices can identify potential hazards — such as gas leaks, equipment faults, or unstable ground — and alert workers before incidents occur.
For instance, at the Escondida copper site in Chile, BHP uses AI-equipped smart helmets to detect signs of driver fatigue through brainwave monitoring. Company-wide AI systems at the site have reportedly saved over three gigalitres of water and 118 gigawatt-hours of energy since 2022.
Energy management is another area where AI adds value. By assessing operational energy usage, AI systems help reduce waste and cut energy costs, easing both financial and environmental burdens.
Minimising Environmental Impact Through AI
AI is helping mining companies reduce their ecological footprint by monitoring environmental variables like air and water quality, as well as ensuring waste is responsibly managed. These systems detect when emissions or discharges exceed legal limits and offer solutions for corrective action.
Rio Tinto, for example, has implemented an AI knowledge assistant capable of searching vast document archives, giving mine planners instant access to decades of operational insights. The company also uses computer vision tools, such as a YOLOv5 model, to process millions of wildlife camera images and track endangered species like the palm cockatoo — a task that previously required months of human labour.
Tailings, the waste materials left after valuable minerals are extracted, also pose a significant environmental risk. AI helps monitor the integrity of tailings dams using embedded sensors that detect changes in moisture, pressure, and structural stability, allowing early intervention to avoid potential disasters.
Though still early in its adoption, AI is already transforming mining practices. By improving resource extraction, safety, and environmental stewardship, the technology offers a glimpse of a future where mining can continue to power modern life — but with greater responsibility and reduced harm.
