Mine Automation: South32’s Hermosa Project and the Future of Mining Investments

The mining industry is undergoing a significant transformation, driven by the need for increased efficiency, improved safety, and enhanced sustainability. Mine automation is at the forefront of this revolution, with companies like South32 leading the way through innovative projects like the Hermosa mine in Arizona. According to recent industry estimates, the global Mining Automation Industry is projected to be worth $5.93 billion in 2030. This blog post will delve into South32’s Hermosa project and explore the future of mining investments in automation.

South32’s Hermosa Project: A Next-Generation Mine

South32’s Hermosa project, located in the Patagonia Mountains of Southern Arizona, is poised to become a flagship example of next-generation mining. As of 2025, it stands as the only advanced mine development project in the United States capable of producing two federally designated critical minerals: manganese and zinc. These minerals are essential for powering the nation’s clean energy future, with manganese being vital for electric-vehicle batteries, steel, and military applications, and zinc crucial for battery storage, solar panels, wind turbines, and other infrastructure.

The Hermosa project is designed with sustainability and minimal environmental impact in mind. Its surface footprint is limited to just 750 acres, a fraction of the size of other mining projects. The project aims to use 90% less water than other mines in the region by prioritizing efficient water use and building one of the first lined, dry stack tailings storage facilities in the United States. South32 is also integrating renewable energy solutions into Hermosa’s design, with the mine being developed with the capability to draw power from renewable energy sources and plans to incorporate electric vehicles into its fleet, reducing greenhouse-gas emissions associated with traditional diesel-powered machinery.

Automation at Hermosa: Driving Efficiency and Safety

Automation is a cornerstone of the Hermosa project, with South32 aiming to create its first ‘next generation mine’ through the use of advanced technologies. Emerson, an industrial technology leader, has been selected to provide automation solutions and engineering expertise for the project’s zinc deposit. This multi-million-dollar automation project will deploy integrated remote operations systems, enabling the production of critical minerals while minimizing environmental impact.

Emerson’s DeltaV™ automation platform will gather real-time data from across the mine into a single secure control system. Operators will remotely monitor and optimize key systems – from ore handling to power and water usage – while running a fully digital, low-emission mining operation. South32 is also constructing a remote operating center in Nogales, AZ, called Centro, which will host approximately 200 full-time staff to remotely monitor and operate underground and surface equipment.

The use of automation at Hermosa is expected to bring several benefits, including:

Increased efficiency: Autonomous machinery can operate 24/7 without breaks or shift changes, leading to higher production rates.
Improved safety: Remote operation reduces the need for human intervention in hazardous areas, minimizing the risk of accidents.
Reduced environmental impact: Automation enables more precise and efficient extraction of resources, minimizing waste and promoting sustainable practices.

The Future of Mining Investments: Automation and Beyond

South32’s Hermosa project exemplifies the growing trend of mining companies investing in automation and other advanced technologies. These investments are driven by several factors, including:

Rising demand for minerals: Global demand for minerals like zinc, silver, and lead is forecast to rise significantly by 2035, driven by industrial growth, electrification, and renewable energy expansion.
Need for greater efficiency: Automation can help mining companies increase productivity, reduce costs, and improve resource utilization.
Focus on safety: Automation can remove workers from dangerous environments, reducing the risk of accidents and injuries.
Emphasis on sustainability: Automation can enable more environmentally responsible mining practices, minimizing waste, reducing emissions, and promoting water conservation.

Some of the key areas of investment in mine automation include:

Autonomous vehicles: Self-driving haul trucks, loaders, and drilling rigs can perform extraction tasks in high-risk areas without direct human intervention.
Drones: Drones can survey areas above or below ground more quickly and safely than traditional methods, gathering critical geological data and monitoring environmental conditions.
Robotics: Robots can perform a variety of tasks in mining operations, from installing explosive charges to maintaining equipment.
AI and predictive analytics: AI-powered systems can analyze data from sensors and other sources to optimize equipment performance, predict maintenance needs, and identify potential hazards.
Remote operations centers: Centralized control centers allow operators to remotely monitor and control mining operations, improving safety and efficiency.

Challenges and Considerations

While mine automation offers numerous benefits, it also presents some challenges and considerations:

High initial investment: Automated systems and AI platforms require major upfront outlays, especially when retrofitting legacy sites.
Integration with legacy systems: Many established mines have numerous legacy IT and operational systems. Integration of new automation technologies can be complex and risk operational disruptions.
Job displacement: Automation can lead to job losses, particularly among lower- and middle-skilled workers. It is important for mining companies to invest in retraining and upskilling programs to help workers transition to new roles.
Skills gap: The rapid pace of automation outstrips the development of necessary technical skills among workers. There is a shortage of employees with the expertise to operate, maintain, and troubleshoot automated systems.
Cybersecurity concerns: As operations become more connected, cybersecurity becomes paramount. Attacks on critical automation systems could have severe operational, economic, or environmental consequences.

The Path Forward

Mine automation is transforming the mining industry, offering the potential for increased efficiency, improved safety, and enhanced sustainability. South32’s Hermosa project is a prime example of how automation can be successfully implemented in a next-generation mine. To fully realize the benefits of mine automation, mining companies must address the challenges and considerations associated with its implementation, including investing in workforce development, ensuring cybersecurity, and engaging with local communities.

By embracing innovation and responsible practices, the mining industry can create a future where automation drives both economic growth and environmental stewardship.