The world’s largest mining companies invest significant resources in finding technological solutions to increase efficiency, safety, and optimize processes. Unmanned technologies have become an integral part of this transformation, replacing classical methods of information collection and reducing time and the need for human resources.
In Ukraine, the first systematic example of drone implementation in the mining industry was the experience of cooperation between DroneUA and Ferrexpo — the largest Swiss mining company operating in Ukraine.
Task
To comprehensively integrate unmanned technologies into Ferrexpo’s production processes on the territory of Poltava and Yeristovo Mining and processing plans.
The project involved:
- selection and delivery of equipment;
- development of a methodology for safe work execution;
- training of personnel in UAV piloting;
- creation of documentation and instructions for integrating the technology into the company’s production processes.
Main goal of the project:
- minimize human presence in hazardous industrial areas during active operation of machinery;
- increase the accuracy of data collection;
- ensure continuity of production processes.
Step-by-step implementation process
Equipment selection
The main criteria were:
- resistance to magnetic anomalies (quarries deeper than 400 m);
- operation in dusty environments;
- resistance to strong winds and low temperatures.
For the work, a drone was selected that underwent testing at a depth of -410 m in the Poltava Mining and Processing Plant and -170 m in the Yeristovo Mining and Processing Plant. The DroneUA team was the first in Ukraine to test and confirm the success of such use.
Development of safety methodology
Together with Ferrexpo, new drone operating rules were created, in particular:
- safe take-off sites were designated;
- the use of lenses with a large focal length was recommended to shoot without descending into the quarry.
Methods comparison
On test sites, the accuracy of traditional surveying and photogrammetric drone surveying was compared. The root mean square error by axis was:
- X: 0.02 m
- Y: 0.03 m
- Z: 0.06 m
The data obtained confirmed compliance with accuracy standards.
Personnel training
The DroneUA team conducted:
- training of UAV operators in safe operation rules;
- preparation in data processing in Pix4D — the world market leader in drone data processing software;
- consultations on data integration into Surpac, AutoCAD Civil 3D, K-mine software.
Process documentation
DroneUA specialists developed occupational safety documentation to legalize the use of drones in the mining industry. This has become a benchmark practice for the entire industry.
Results
The DroneUA solution enabled Ferrexpo to achieve several strategic goals:
- Safety — minimizing risks for personnel.
- Production continuity — no downtime of quarry equipment.
- Productivity — speeding up surveying by 90%.
- Quality — high detail of 3D models.
- Automation — route navigation and standardized process.
- Documentation — a complete set of instructions and methodologies was created.
Conclusion
The project of implementing unmanned technologies at Ferrexpo enterprises has become for the Ukrainian mining industry not just a stage of automation but proof that drones are able to change industrial processes at a fundamental level.
Systematic integration of modern solutions, the development of unique safety methodologies, and the standardization of procedures — all this lays the foundation for a new production culture, at the center of which are human safety, technological resilience, and maximum efficiency.
DroneUA will continue to create new standards of technological capabilities and support business in the transformation toward a more sustainable, safe, and productive future.
Information about the project participant companies
*Ferrexpo — a company specializing in the production and export of iron ore pellets. It is the largest exporter of pellets in the CIS. The company’s main asset is located in Ukraine — PJSC “Poltava Mining and Processing Plant” (PJSC “PGOK”). The headquarters is located in Switzerland. The main consumers of the products are companies from Austria, Serbia, Slovakia, the Czech Republic, Germany, and other European countries, as well as China, India, Japan, and other Asia-Pacific countries.
*DroneUA — a leading international group of companies that is a front-runner in providing integrated unmanned technologies, robotics, energy solutions, and data analytics across various sectors of agriculture, energy, infrastructure, and security. DroneUA has its own engineering and production divisions as well as an open data center. Key areas of work include technology distribution, unmanned solutions, digital analytics, engineering innovations, its own satellite and drone data processing center, and customer service.
