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TESTING ALTERNATIVE TECHNOLOGIES TO REPLACE CURRENT BELT SAMPLING METHODS

TESTING ALTERNATIVE TECHNOLOGIES TO REPLACE CURRENT BELT SAMPLING METHODS

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TECHNOLOGIES ON THE FACE

Ground Penetrating Radar
LIDAR
STRATAFY SEEKER
ACAUSTIC TECHNOLOGIES
GRADE ESTIMATION
E-PEGS
E-PEGS
Challenge

The key challenge is gaining real-time insight into conditions at the mining front, particularly geological and ground stability factors, to enhance operational efficiency and safety. A primary concern is preventing falls of ground (FoG), a persistent and critical risk in underground mining. Several factors hinder these objectives, including:

  • Harsh underground conditions affect sensor performance and durability.
  • Mining activity interference (noise, vibrations) disrupts data accuracy.
  • Slow data processing delays real-time decision-making.
  • Limited portability makes some tools difficult to use underground.
  • Georeferencing issues reduce mapping accuracy without GPS.
  • High costs limit adoption, especially for smaller mines.
  • Training needs for operators to use and interpret data effectively.

Future efforts focus on AI integration, cost reduction, improved durability, and real-time processing to enhance safety and efficiency.

Research and development

Ongoing research under the Advanced Orebody Knowledge (AOK) Programme focuses on refining and integrating technologies to improve geological understanding and safety at the mining face, such as:

  • Ground Penetrating Radar (GPR) – The research and development of Ground Penetrating Radar (GPR) focused on improving its capability to identify geological discontinuities, lithological units, and fractures within underground mining environments, successfully leading to enhanced geological mapping, risk assessment, and operational safety.
  • LiDAR – The research and development of LiDAR focused on optimising its application for underground geological mapping, enhancing georeferencing accuracy, improving portability, and integrating it with other geophysical technologies to create detailed 3D models for mining operations.
  • ITAD - The research and development of the Integrated Thermal Acoustic Device (ITAD) involved testing its ability to detect loose rock using both thermal imaging and acoustic analysis; however, thermal imaging proved unsuccessful and was discontinued, while further work continues to refine its acoustic detection capabilities for improved safety in underground mining.
  • Stratafy Seeker – Designed to create real-time 3D models for hazardous rock identification, with advancements in scanner miniaturisation, processing speed, and user ergonomics to enhance underground usability and improve fall-of-ground detection.
  • Laser-Induced Breakdown Spectroscopy (LIBS) – LIBS was evaluated for real-time mineral analysis and PGM grade assessment, showing potential for platinum group metal testing but proving unsuitable for gold chip sampling, with further trials planned to refine its application in mining.
  • E-PEG - The Real-Time Location System (RTLS), developed as Enhanced Positioning for GPS-Deprived Environments (E-PEGS), focused on improving underground tracking through Ultra-Wideband (UWB) technology, enhancing deployment speed, scalability, real-time monitoring, and operational safety in mining.
Findings

With the optimal extraction and ‘’zero harm’’ objectives, technologies are being investigated, such as the Ground Penetrating Radar, to assist with identifying potential hazards on the mining face. There will also be a focus on positioning systems to enable scanning/assessment of the hanging wall integrity. GPR 3D modelling trial surveys will be conducted and, with Infrared (IR)/Thermography, one would be able to enrich GPR information. Attention will also be given to positioning systems so as to enable scanning/assessment of the hanging wall integrity. The deployment platforms with associated positioning systems will enable fast acquisition of georeferenced 3D data sets.

Future efforts focus on AI integration, cost reduction, improved durability, and real-time processing to enhance safety and efficiency.

Status
  • Ground Penetrating Radar (GPR) – Research completed, successfully tested for identifying fractures and lithological units.
  • LiDAR – Research completed, proven effective for 3D geological mapping.
  • Integrated Thermal Acoustic Device (ITAD) – Thermal imaging was discontinued due to unsuccessful results. Further acoustic analysis is ongoing to improve hazard detection.
  • Stratafy Seeker – Functional real-time 3D modelling tool; optimising processing speed and user ergonomics currently in development.
  • Laser-Induced Breakdown Spectroscopy (LIBS) – Under evaluation for PGM grade testing; further trials planned for 2025.
  • E-PEGS is progressing toward the next phase of hardware development for the 2025/26 period.
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Ground Penetrating Radar

LIDAR
Stratafy Seeker
Acoustic Technologies
Grade Estimation
E-PEGS
Challenge

The Advanced Orebody Knowledge (AOK) Programme, in collaboration with the Council for Scientific and Industrial Research (CSIR), has conducted extensive research on Ground Penetrating Radar (GPR) to improve geological mapping, rock mass stability assessment, and hazard identification in underground mining. The research has focused on addressing technical limitations and refining applications to enhance mining efficiency and safety.

Research and development
  • Initial assessments of 3D GPR trials were conducted at underground hard rock mines (gold and platinum) to test excavation stability and improve risk assessment models.
  • Thermal scanning was explored as a complementary technology to enhance GPR data interpretation, aiming to detect geological features close to the hangingwall. However, experimental studies at a Platinum mine in Rustenburg faced challenges due to shotcrete, mesh, and roof bolts interfering with scans.
  • GPR applications expanded to include:
    • Identifying lithological units and mapping fractures in the mining face
    • Detecting footwall discontinuities and problem zones, such as Khaki Shale, which has caused ground stability issues.
    • Trials at several mines confirmed GPR’s potential for improving structural understanding and risk mitigation.
  • Research focused on integrating GPR outputs into a 3D visualization environment by combining GPR with mine plans and seismic data.
    • Seismic attributes in real GPR data were evaluated, showing potential for enhancing subtle structural feature detection.
    • Integration with LiDAR was explored to develop a unified mapping tool, improving georeferencing and visualization.
  • Research efforts were completed with a final GPR guideline report, providing best practices to improve implementation in mining operations.
  • Knowledge transfer efforts ensured that mining teams could effectively use the technology, with training materials and webinars made available
Findings
  • Successfully identified geological discontinuities (faults, fractures, lithological variations) in the hangingwall (1-3m depth).
  • Demonstrated GPR’s ability to detect problem areas, such as Khaki Shale, which previously caused mining sterilisation.
  • Improved footwall mapping, enabling better planning and reducing rockfall risks.
  • Generated accurate 3D subsurface models, integrated with other geophysical tools.
  • Guidelines developed for best practices, including survey logistics, data output optimisation, and visualisation.
  • Webinars and training materials were produced to support industry adoption of GPR for enhanced safety and efficiency.
Status
  • GPR has proven to be a valuable tool for underground mining, enhancing risk assessment, geological understanding, and operational safety, with ongoing developments to optimize its application.
  • Field trials confirmed GPR's effectiveness in detecting fractures, lithological units, and geological discontinuities.
  • Standardised guidelines established for survey logistics, data processing, and interpretation.
  • Integrated with LiDAR and seismic methods, enhancing 3D geological modelling.
  • Training materials and webinars developed to support industry adoption.
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lidaR

Ground Penetrating Radar
Stratafy Seeker
Acoustic Technologies
Grade Estimation
E-PEGS

LiDAR (Light Detection and Ranging) is a powerful tool in mining, particularly in the Advanced Orebody Knowledge (AOK) Programme. Its primary role is to enhance geological mapping, safety, and operational efficiency by providing high-resolution 3D models of underground and surface environments

Application in Mining
  • Geological Mapping: LiDAR generates detailed 3D models of tunnels, rock structures, and orebodies.
  • Safety Enhancement: Helps detect unstable rock formations and supports hazard identification to prevent falls of ground (FOG).
  • Surveying & Georeferencing: Overcomes the challenge of no GPS underground by assisting in accurate mapping of mine workings
  • Technology Integration: Works alongside GPR, ERT, and TSP to improve geological interpretation.
Challenges identified
  • High Equipment & Processing Costs: LiDAR technology remains expensive, limiting widespread adoption.
  • Complex Data Processing: Large point cloud datasets require specialized expertise and computing power.
  • Operational Limitations: Dust, humidity, and confined underground spaces can affect scan quality
  • Slow Industry Adoption: Traditional mapping techniques are still dominant in some mining operations.
Research and development
  • Research was undertaken by the University of Johannesburg (UJ) to explore LiDAR as an alternative mapping tool for georeferencing and geological surveys.
  • Portable LiDAR systems like GeoSLAM were tested by the CSIR, providing high-resolution point clouds in a shorter time.
  • Research continues into integrating LiDAR with AI-driven analysis, automation, and predictive modelling.
Status

LiDAR is a game-changer in mining, offering faster, safer, and more accurate geological insights. While challenges exist, continued research, and integration with AI-driven mining solutions are making it a key component of modern, efficient, and sustainable mining practices.

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Stratafy Seeker – A Rock Hazard Identification Technology

Ground Penetrating Radar
LIDAR
Acoustic Technologies
Grade Estimation
E-PEGS
Challenges identified

The Stratafy Seeker, developed through Stratafy Solutions’ research and development efforts, is a cutting-edge solution aimed at enhancing mine safety and operational efficiency. By combining photogrammetry, real-time 3D modelling, and AI-driven analysis, it provides a proactive approach to fall of ground prevention and risk mitigation in underground mining.

Research and development

The Stratafy Seeker is a geotechnical hazard detection system developed as part of the Advanced Orebody Knowledge (AOK) Programme. It was a finalist in the 2022 Fall of Ground (FOG) Challenge, aimed at improving rock hazard identification and visualisation in mining environments. The research and development of this technology is being conducted by Stratafy Solutions.

The Stratafy Seeker uses a three-pronged approach:

  • Digital Pinch-Bar: A syntopic camera array that scans rock surfaces for potential hazards.
  • Photogrammetric Processing Platform: Converts images into 3D models for detailed rock structure analysis.
  • Local and Cloud-Based Processing: Provides real-time feedback on hazardous areas.
Development and Testing
  • A scanning head prototype was developed to capture high-resolution 3D point clouds.
  • Field tests at mining operations confirmed accurate rock hazard detection.
  • The Processing Pod was introduced to deliver real-time visual feedback to miners.
Status

Currently in Development 

  • Building a Scanner-Specific Processing
  • Creating a Plug-In for the Stratafy Platform
  • Further refining and enhancing the device to improve accuracy and usability
  • Exploring successful integration into operational mining environments.
  • Advancing its Technology Readiness Level (TRL) to ensure it is industry-ready.
  • Successfully deploying a Minimum Viable Product (MVP) for real-world application.
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Acoustic Technologies

Ground Penetrating Radar
LIDAR
Stratafy Seeker
Grade Estimation
E-PEGS
Challenges identified
  • Fall-of-Ground (FOG) Hazards – Manual sounding methods are subjective, leading to missed hazards. Acoustic technology provides consistent, data-driven detection.
  • Inefficiency in Barring Practices – Miners rely on sound perception, which is prone to human error. AI-based analysis improves accuracy and reliability.
  • Delayed Hazard Detection – Traditional methods take time to process data. Acoustic technology enables instant classification for real-time decision-making.
  • Limited Digital Integration – Current hazard detection is manual. Using mobile devices (iPhones, iPads) makes it affordable and scalable.
Research and development 

The Integrated Thermal Acoustic Device (ITAD) was developed as part of the Advanced Orebody Knowledge (AOK) Programme, with research conducted by the Council for Scientific and Industrial Research (CSIR). This technology aims to enhance underground safety by detecting potentially hazardous loose rocks.

Key Findings from ITAD (Acoustic Component)
  • Acoustic Subsystem Success: The acoustic analysis successfully distinguished between safe and unsafe rock conditions based on frequency response, with a machine learning model.
  • Thermography Challenges: The thermal imaging component faced significant limitations, including a restricted field of view and difficulty in accurately identifying loose rock areas. As a result, thermography was not successful and was discontinued, while the acoustic technology continued to be developed and refined.
  • Field Trials: The ITAD device demonstrated better performance in Platinum and Chrome mining environments compared to Gold mining, with its effectiveness influenced by rock type and excavation conditions.
  • Impact of Barring Practices: The type and length of pinch bars used in underground operations affected the accuracy of acoustic measurements.
Planned Developments
  • Remote Tapping System: Introducing a mechanical impact device to replace manual tapping, ensuring consistent and repeatable acoustic measurements.
  • Noise Reduction Strategies: Developing advanced filtering techniques to eliminate background noise and enhance data reliability.
  • Real-Time Data Transmission: Investigating wireless communication solutions to provide instant feedback on rock stability conditions.
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Laser-Induced Breakdown Spectroscopy (LIBS) Technology

Ground Penetrating Radar
LIDAR
Stratafy Seeker
Acoustic Technologies
E-PEGS

LIBS is a spectroscopic analytical technique used to determine the elemental composition of materials. It involves focusing a high-energy laser pulse on a sample, creating a small plasma on its surface. As the plasma cools, it emits characteristic light wavelengths corresponding to the elements present in the sample.

Challenge

There is a need for Real-Time, On-Site Ore Analysis

  • Traditional ore analysis methods (e.g., fire assay, XRF) require sample preparation and lab testing, causing delays in decision-making.
  • LIBS offers instant, non-destructive elemental analysis, making it ideal for real-time ore grading and quality control.
  • Faster results mean better mine planning and reduced ore dilution.

Future efforts focus on AI integration, cost reduction, improved durability, and real-time processing to enhance safety and efficiency.

Research and development Focus Areas:
  • Real-Time Ore Analysis – Develop portable LIBS devices for instant underground ore grading.
  • PGMs & Gold Testing – Assess LIBS accuracy for platinum, palladium, rhodium, and gold.
  • Overcoming Challenges – Improve data processing, reduce interference from dust/moisture, and enhance depth penetration.
  • Smart Mining Integration – Combine LIBS with AI, hyperspectral imaging, and automation for better orebody characterization.
  • Cost & Sustainability – Reduce reliance on chemical-based lab assays and optimize ore selectivity.
  • Lab Testing – Compare LIBS results with fire assay & XRF.
  • Field Trials – Test in real mining conditions.
  • AI & Data Processing – Improve spectral accuracy using machine learning.
  • Industry Adoption – Optimise LIBS for routine grade control.

e-pEGS

Ground Penetrating Radar
LIDAR
Stratafy Seeker
Acoustic Technologies
Grade Estimation

Global Positioning System (GPS) technology is widely used for navigation and location tracking. However, GPS signals cannot penetrate solid materials such as rock and soil, making it ineffective for underground mining and tunneling operations. To address this limitation, Reutech Mining has developed an Ultra-Wideband (UWB) location tracking system, which provides accurate real-time tracking in GPS-deprived environments.

This project aims to enhance the existing Reutech Mining Real-Time Location System (RTLS) to improve efficiency, user-friendliness, and industry-wide applicability. The enhancements will focus on three key objectives: auto-locating anchors, universal data export formats, and integrating server functionalities into tablet computers.

Challenges identified

GPS signals cannot penetrate solid materials such as rock and soil, making them ineffective for underground mining operations.

Traditional location tracking methods are unreliable or require costly infrastructure.

  • Auto-Locating Anchors Reduced Setup Time – Faster deployment and higher accuracy.
  • Universal Data Export Improved Compatibility – Enabled CSV/XML exports, making data easier to integrate with mining software.
  • Tablet Integration Replaced Server – Eliminated bulky hardware, making the system portable and user-friendly.
  • High Tracking Accuracy – Provided real-time monitoring (20 Hz) with stable underground connectivity.
  • Improved Scalability & Adaptability – Easily expanded for larger mining operations and various tunnel layouts.
  • Battery-Powered System – Operated without external power, ensuring uninterrupted tracking.
  • Enhanced Safety & Efficiency – Enabled faster emergency response and optimized resource management.
Status

To continue with the next phase of Hardware Development during the 2025/26 period:

  • Design & Prototype Hardware – Develop and test components for underground deployment.
  • Validate Performance – Conduct lab and field tests to ensure durability and accuracy.
  • Optimize & Refine – Improve power efficiency, connectivity, and reliability.
  • Manufacturing & Production – Finalize specs and begin production.
  • Integration & Deployment – Ensure seamless hardware-software compatibility and real-world testing.
  • Market Launch – Prepare for commercial rollout and user training.

Kumu

Rock Hazard Identification Challenge (RHID)
AOK Showcase Event
Kumu

The Advanced Orebody Knowledge (AOK) programme has utilised Kumu, a visual mapping platform, to clearly represent complex geoscientific data and relationships. Kumu transforms intricate datasets into accessible, interactive visuals that effectively support stakeholder mapping, systems thinking, and relationship analysis, enhancing communication, strategic decision-making, and alignment across diverse sectors.

The identification of innovative technologies was spearheaded by the Research Institute for Innovation and Sustainability (RIIS) in collaboration with the Council for Scientific and Industrial Research (CSIR). Through their collaborative efforts, a comprehensive technology scouting process was undertaken, resulting in 171 technologies being catalogued and integrated into the Kumu ecosystem map. This interactive visualization serves as a powerful tool for fostering innovation, collaboration, and strategic alignment within the mining industry.

experience kumu

Rock Hazard Identification Challenge (RHID)

Rock Hazard Identification Challenge (RHID)
AOK Showcase Event
Kumu
Purpose:
    • To identify, develop, and implement innovative technological solutions for detecting and managing rock hazards in underground mining, specifically aimed at reducing Falls of Ground (FOG).
 
Implementation:
    • Conducted collaboratively by the Advanced Orebody Knowledge (AOK) programme, the Minerals Council South Africa (FOGAP), and industry partners including Sibanye-Stillwater and Impala Platinum.
    • Global technology scouting and expert consultations identified promising international innovations.
    • Invited submissions from global innovators, evaluated by an expert panel during a virtual pitching event.
 
Outcomes:
    • Successfully attracted innovative solutions aimed at real-time inspection and improved hazard detection.
    • Reutech Mining emerged as the challenge winner.
    • Decision made to host an additional showcase event in 2024, following the success of the initial challenge.
 
Current Status:
    • Showcasing hosted in 2024 with existing and emerging geological hazard identification technologies.

The RHID challenge significantly supports safer mining operations through international collaboration and innovative technological advancements.

Advanced Orebody Knowledge (AOK) Showcase Event

Rock Hazard Identification Challenge (RHID)
AOK Showcase Event
Kumu

 

The mining industry faces challenges from unforeseen geological conditions affecting safety, productivity, and profitability. To address this, the Advanced Orebody Knowledge (AOK) programme under the Mandela Mining Precinct (MMP) has developed innovative geoscientific technologies aimed at creating a transparent “glass rock” environment for precise mine planning and risk management.

The recent AOK Showcase Event highlighted these technological advancements, bringing together academia, mining professionals, government, and technology providers. It featured:

  • Attendance: 343 participants (476 registered), including academia, mining experts, government officials, and tech providers.
  • Technology Exhibits: 36 exhibitors showcased advanced geoscientific solutions.
  • Technology Scouting: 171 innovative technologies identified, supporting safer and more efficient mining practices.

Feedback was overwhelmingly positive, emphasizing the importance of ongoing collaboration and knowledge-sharing within the industry.

Recommendations:

  • Establish the showcase as an annual event.
  • Continue scouting and integrating advanced technologies.
  • Strengthen industry collaboration through regular knowledge dissemination events.

This event significantly advanced efforts to modernize mining operations through technology and collaboration, shaping the industry’s future.