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Data Insights Innovation in mining: tunnel boring machines

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However, not all innovations are equal and nor do they follow a constant upward trend. Instead, their evolution takes the form of an S-shaped curve that reflects their typical lifecycle from early emergence to accelerating adoption, before finally stabilizing and reaching maturity.

Identifying where a particular innovation is on this journey, especially those that are in the emerging and accelerating stages, is essential for understanding their current level of adoption and the likely future trajectory and impact they will have.

45+ innovations will shape the mining industry

According to GlobalData’s Technology Foresights, which plots the S-curve for the mining industry using innovation intensity models built on over 81,000 patents, there are 45+ innovation areas that will shape the future of the industry.

Within the emerging innovation stage, tunnel ventilation systems, remote tunnel monitoring, and mine drainage systems are disruptive technologies that are in the early stages of application and should be tracked closely. Lithium recovery, battery metal recycling and tunneling, and anchoring machine are some of the accelerating innovation areas, where adoption has been steadily increasing. Among maturing innovation areas are hydrometallurgical extraction and hybrid industrial vehicles, which are now well established in the industry.

Innovation S-curve for the mining industry

Tunnel boring machines is a key innovation area in mining

Tunnel boring machines (TBMs) are used instead of drilling and blasting through rock and conventional mechanical excavation in soft ground. TBMs used in mining projects differ from those used in typical civil engineering applications. TBMs have been used for a variety of purposes as part of new and expanding mining projects, including new access, ore and waste conveyance, drainage, exploration, and water diversion.

Some of the benefits of using TBMs include higher and more sustainable progress rates in generally good quality hard rock conditions. Lower ventilation is required, allowing for the construction of smaller tunnels and improved health conditions for workers who are not exposed to blast smoke and fumes. They also produce a smooth tunnel wall, which lowers the final lining cost. TBMs significantly reduce the total excavation time of long tunnels when compared to conventional excavation methods.

GlobalData’s analysis also uncovers the companies at the forefront of each innovation area and assesses the potential reach and impact of their patenting activity across different applications and geographies. According to GlobalData, there are 140+ companies, spanning technology vendors, established mining companies, and up-and-coming start-ups engaged in the development and application of tunnel boring machines.

Key players in tunnel boring machines – a disruptive innovation in the mining industry

‘Application diversity’ measures the number of applications identified for each patent. It broadly splits companies into either ‘niche’ or ‘diversified’ innovators.   

‘Geographic reach’ refers to the number of countries each patent is registered in. It reflects the breadth of geographic application intended, ranging from ‘global’ to ‘local’.  

Patent volumes related to tunnel boring machines

Komatsu and Sandvik are among the leading patent filers in in tunnel machines. Amongst the innovations, Komatsu has partnered with Codelco to test a new tunnel excavation method using Komatsu's newly developed mining TBM. The mining TBM is equipped with new technologies that allow it to adapt to small curves, reverse direction, and pass-through intersections in hard rock tunnel excavation. This new technology increases equipment flexibility and allows tunnels to be excavated in accordance with the more unique designs of each mine. The trial, which will begin in 2024 at Codelco's Chuquicamata mine in Chile, aims to accelerate the potential implementation of the new technology.

Similarly, Sandvik's tunnelling jumbos provide high productivity and dependability using face drilling, mechanized longhole drilling and bolting. The company’s tunnelling machines include DT1232i, DT923i (fully automated), DT1231, DT1131 (three-boom, electro-hydraulic), and DT912D (self-contained, air-mist flushing, diesel-hydraulic high reach single boom).

Some other key patent filers in tunnel boring machines include China Railway Group, Herrenknecht and Atlas Copco.

In terms of application diversity, Hongrun leads the pack, while Alleima and Zhejiang Communications Construction Group stood in the second and third positions, respectively. By means of geographic reach, XCMG Construction Machinery held the top position, followed by China Railway Construction and China Railway First Group.

To further understand the key themes and technologies disrupting the mining industry, access GlobalData’s latest thematic research report on Mining.

GlobalData, the leading provider of industry intelligence, provided the underlying data, research, and analysis used to produce this article.

GlobalData’s Patent Analytics tracks patent filings and grants from official offices around the world. Textual analysis and official patent classifications are used to group patents into key thematic areas and link them to specific companies across the world’s largest industries.