Chiba Chengo (standing) and a colleague discuss the distribution of current production via the mobile Manufacturing Execution System (NFCA)?

In the digital control centre of the Chambishi copper mine’s southeast deposit in Zambia, a massive screen displays the status of various mining activities in real time: extraction, digging, machine operation, and transport.??

Although machinery sounds can still be heard in the underground galleries, this “digital mine” relies more on an integrated computerised system than on traditional manual labour. “We can observe and understand underground activities in detail without going underground,” explained Dean Mwelwa, an executive at NFC Africa Mining (NFCA), pointing to the control screen.?

NFCA, a joint investment between China Nonferrous Metal Mining and Zambia Consolidated Copper Mines Investment Holdings, was tasked with redeveloping the Chambishi copper mine, which had been closed for over a decade. After 13 years of inactivity, the mine reopened in July 2003, becoming the first overseas non-ferrous metal operation managed by a Chinese company. Following the reopening of the main deposit, the western and southeastern deposits were gradually developed.?

In August 2018, the commissioning of the southeast deposit marked the launch of Africa’s first-ever “digital mine project.” This digitisation enabled extensive mechanisation and increased automation, improving safety and modernising the Zambian mining industry.?

A pioneering project?

“As early as 2016, digitalisation was initiated to address complex geological conditions, particularly a high presence of underground water,” said Zhang Jinzhong, then head of NFCA’s southeast deposit control centre. Previously, the mine operated according to a traditional model with dispersed management and limited efficiency. To modernise its operations, NFCA conducted field studies at leading mines in Sweden, Finland, and South Africa. After an in-depth analysis, it chose to integrate information and automation technologies into its production and management system.?

The company digitally modernised the main and west fields using the Manufacturing Execution System (MES) platform and mobile applications, creating a responsive, transparent, and accurate production environment. Building on this experience, it then deployed hardware and software tools such as the Industrial Internet, big data, cloud services, and 3D modelling at the southeast deposit. This advanced integration of intelligent equipment, digital technologies, and advanced extraction methods enabled the construction of a new generation of “digital mines.”?

In just a few years, the results have been spectacular. In the west deposit, annual production capacity has exceeded initial forecasts by 15 percent. Extraction efficiency has risen from 2.68 to 7.58 tonnes per day per worker, an increase of 2.83 times.?

The southeast deposit uses some of the world’s most advanced mining automation equipment, enabling remote extraction. A single machine achieves an exceptional output of 36,640 tonnes per month. Ore processing maintains a stable daily capacity of over 10,000 tonnes. In 2024, total production from driverless equipment reached 800,000 tonnes, or 20 percent of annual production.?

According to Zhang, this digital mine also addresses a major challenge for the sector: safety. “Previously, temperature and ventilation readings were taken manually. Today, this data is monitored in real time, enabling us to react quickly to any anomalies,” he explained.?

On 28 June 2024, Hapenga Kabeta, permanent secretary at Zambia’s Ministry of Mines and Mineral Development, hailed NFCA’s progress, “The technologies applied here are not only pioneering in Zambia, but also cutting edge in Africa. By putting safety first and monitoring mining operations in real time, NFCA has proven that it is possible to operate a reputable mine in the country!”?

NFCA is also committed to local development by supporting Zambian suppliers. In 2021, out of 313 qualified suppliers, 298 were local, representing 95 percent of purchases. Local production of essential materials has been encouraged, strengthening the country’s industrial capacity. The company has also played a leading role in promoting large-scale, automated, and intelligent mining machinery, as well as modern extraction and processing systems, enabling the Zambian mining industry to reach international standards.?

A view of NFC Africa Mining in Kitwe, Copperbelt Province, Zambia, on 3 June 2024 (NFCA)?

Talent training?

From the outset, NFCA formed a team of instructors comprising Chinese and Zambian staff, using a training model combining “theory, simulation, and practice” to impart operational skills to employees and develop a highly skilled Zambian workforce. In 2016, Zambian employee Sitali was sent, along with 23 Chinese and Zambian colleagues, to Finland for smart equipment training. Since then, he has become a trainer in trackless equipment.?

A vocational training centre was opened in 2018 to provide training in digital mining, safety, and technical skills. In collaboration with the Zambia Mining Safety Authority, it also offers open training courses, helping to raise standards across the sector. In 2023 alone, more than 14,000 people were trained.?

Local workers are the main beneficiaries of this transformation. Chiba Chengo, an automation technician in the mining department of the southeast deposit, joined NFCA in September 2020. He studied digital mining technologies and management skills, focusing on the use of MES and automated mining systems. Together with his team, he has continuously optimised production processes, becoming a key player in the digital transformation of mining in Zambia.?

The company has also invested millions of dollars in state-of-the-art training equipment, such as trackless machine simulators and virtual reality (VR) safety training devices, a first in Zambia. According to Zhang, thanks to VR, workers can “experience” the consequences of dangerous behaviour, thereby raising safety awareness and encouraging safe operating practices.?

“We discovered innovations and advanced technologies, including simulation-based training methods, the use of VR, and the automation of mining operations. We are extremely proud of this investment,” said Jito Kayumba, special envoy of the Zambian President, during a visit to NFCA on 25 June 2024.?

At the launch of the southeast deposit, former Chinese ambassador to Zambia Li Jie praised NFCA’s contribution to the country’s economic and social development. He pointed out that the mine is a model of automation and training, which has led to the emergence of a local pool of highly qualified talent.

The Chambishi digital mine represents a genuine technological revolution for the Zambian mining industry. Thanks to NFCA’s expertise and investment, the country has modernised its infrastructure, improved worker safety, and trained a new generation of professionals. This pioneering project paves the way for more sustainable, efficient, and competitive mining while strengthening the economic and human ties between China and Zambia.

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