Smart control and automated regulation in the coal industry: transforming industrial process systems in the digital age
V.L. Kudryavtsev1, Yu.V. Zabaikin2 , Z.A. Arsakhanova3, O.V. Chumakova4
1 All-Russian State University of Justice, St. Petersburg Institute (branch), St. Petersburg, Russian Federation
2 National University of Oil and Gas “Gubkin University”, Moscow, Russian Federation
3 Kadyrov Chechen State University, Grozny, Russian Federation
4 Moscow State University of Civil Engineering (National Research University), Moscow, Russian Federation
Russian Mining Industry №3 / 2025 p.153-163
Abstract: The coal industry is undergoing a radical transformation under the impact of digital technologies, which require a reassessment of traditional approaches to management and regulation of industrial processes. Smart control systems are becoming a critical factor in improving the efficiency, safety and environmental sustainability of coal mining companies. The purpose of this study is to develop a conceptual model to integrate Industry 4.0 technologies into the coal mine management system to optimize production processes and minimize environmental risks. The study applied methods of system analysis, mathematical modelling, expert assessment, and comparative analysis of international practices. The empirical base includes data from 52 coal mining operations in Russia, China, Australia, and the United States for the period from 2022 to 2024. The results show that the introduction of smart systems can reduce operating costs by 15–23%, increase productivity by 28–38% and reduce the number of emergencies by 72%. The efficiency coefficient of automated control reaches 0.86–0.94 under optimal operating conditions. The discussion reveals the potential for creating fully autonomous mines by 2028, however, it emphasizes the need to address cyber security issues and adapt the regulatory framework. The results obtained provide a theoretical basis for the development of a national strategy for digital transformation of the coal industry and can be used in designing a newgeneration of smart mining complexes
Keywords: smart control, automated regulation, digital transformation, coal industry, Industry 4.0, artificial intelligence, autonomous systems
For citation: Kudryavtsev V.L., Zabaikin Yu.V., Arsakhanova Z.A., Chumakova O.V. Smart control and automated regulation in the coal industry: transforming industrial process systems in the digital age. Russian Mining Industry. 2025;(3):153–163. (In Russ.) https://doi.org/10.30686/1609-9192-2025-3-153-163
Article info
Received: 30.03.2025
Revised: 27.05.2025
Accepted: 27.05.2025
Information about the authors
Vladislav L. Kudryavtsev – Dr. Sci. (Law), Professor, Department of Criminal Law and Procedures, All-Russian State University of Justice, St. Petersburg Institute (branch), St. Petersburg, Russian Federation; https://orcid.org/0000-0003-3141-2676; e-mail: kudryavcev@rpa.ru
Yury V. Zabaikin – Cand. Sci. (Econ.), Associate Professor, Department of Automation of Technological Processes, National University of Oil and Gas “Gubkin University”, Moscow, Russian Federation; e-mail: zabaikin@gubkin.ru
Zina A. Arsakhanova – Dr. Sci. (Econ.), Department of Finance, Credit and Antitrust Regulation, Kadyrov Chechen State University, Grozny, Russian Federation; e-mail: arsahanova@chesu.ru
Olga V. Chumakova – Cand. Sci. (Law), Associate Professor, Associate Professor, Department of Social, Psychological and Legal Communications, Moscow State University of Civil Engineering (National Research University), Moscow, Russian Federation; https://orcid.org/0000-0003-4839-7628; e-mail: 7406976@gmail.com
References
1. Wang G., Ren H., Zhao G., Zhang D., Wen Z., Meng L., Gong S. Research and practice of intelligent coal mine technology systems in China. International Journal of Coal Science & Technology. 2022;9:24. https://doi.org/10.1007/s40789-022-00491-3
2. Brodny J., Tutak M. Challenges of the polish coal mining industry on its way to innovative and sustainable development. Journal of Cleaner Production. 2022;375:134061. https://doi.org/10.1016/j.jclepro.2022.134061
3. Onifade M., Adebisi J.A., Shivute A.P., Genc B. Challenges and applications of digital technology in the mineral industry. Resources Policy. 2023;85(B):103978. https://doi.org/10.1016/j.resourpol.2023.103978
4. Yuan Y., Cheng G., Peng W., Yang X., Du Y. Investment strategies for sustainable safe development of Chinese coal mine employees driven by digital intelligence. Frontiers in Public Health. 2024;12:1464930. https://doi.org/10.3389/fpubh.2024.1464930
5. Salieiev I. Organization of processes for complex mining and processing of mineral raw materials from coal mines in the context of sustainable development. Mining of Mineral Deposits. 2024;18(1):54–66.
6. Chen L., Xie Y., He Y., Ai Y., Tian B., Li L. et al. Autonomous mining through cooperative driving and operations enabled by parallel intelligence. Communications Engineering. 2024;3:75. https://doi.org/10.1038/s44172-024-00220-5
7. Efimov V.I., Efimova N.V. Digital transformation of open-pit coal mining in Russia. In: Zavyalova E.B., Popkova E.G. (eds) Industry 4.0. Palgrave Macmillan, Cham; 2021, pp. 235–248. https://doi.org/10.1007/978-3-030-75405-1_21
8. Yarkova T.A., Dykusova A.G., Kolesnikova T.V. Opportunities and prospects of digitalization in Russian coal industry. In: Nechaev A.S., Bunkovsky V.I., Beregova G.M., Lontsikh P.A., Bovkun A.S. (eds). Trends and innovations in economic studies: European Proceedings of Social and Behavioural Sciences. 2020, vol. 96, рр. 688–697. https://doi.org/10.15405/epsbs.2020.12.90
9. Bai J., Zheng D., Jia C. Safety technology risks and countermeasures in the intelligent construction of coal mines. Geofluids. 2022;2022:4491044. https://doi.org/10.1155/2022/4491044
10. Codoceo-Contreras L, Rybak N, Hassall M. Exploring the impacts of automation in the mining industry: A systematic review using natural language processing. Mining Technology. 2024;133(3):191–213. https://doi.org/10.1177/25726668241270486
11. Davidson M.R. Managing the decline of coal in a decarbonizing China. Wiley Interdisciplinary Reviews: Climate Change. 2024;15(6):e918. https://doi.org/10.1002/wcc.918
12. Jiskani I.M., Cai Q., Zhou W., Shah S.A.A. Green and climate-smart mining: A framework to analyze open-pit mines for cleaner mineral production. Resources Policy. 2021;71: 102007. https://doi.org/10.1016/j.resourpol.2021.102007
13. Zhang K., Kang L., Chen X., He M., Zhu C., Li D. A review of intelligent unmanned mining current situation and development trend. Energies. 2022;15(2):513. https://doi.org/10.3390/en15020513
14. Young A., Rogers P. A review of digital transformation in mining. Mining, Metallurgy & Exploration. 2019;36(4):683–699. https://doi.org/10.1007/s42461-019-00103-w
15. Miao D., Lv Y., Yu K., Liu L., Jiang J. Research on coal mine hidden danger analysis and risk early warning technology based on data mining in China. Process Safety and Environmental Protection. 2023;171:1–17. https://doi.org/10.1016/j.psep.2022.12.077