Full-cycle engineering: TAPP Group experience

Hello, tekkix!

This is Dmitry Lokhov, CEO of TAPP Group. In the last article, we discussed import substitution in the mining and processing industry. Today, it's about a more fundamental approach. The mining and processing industry is on the brink of a revolution: where it used to take 5–7 years to build a mining and processing plant, some projects are now being completed in just a year. How is this possible?

The answer lies in discarding outdated approaches where geologists, designers, and builders work in isolation. Years of experience and expertise at TAPP Group have shown: integrating all stages into a single cycle reduces timelines from 3–5 years to 6–12 months.

This article will be of interest to:

• Technical directors and mining plant managers — we’ll explain how to shorten project timelines and reduce budget risks;

• Chief engineers and designers — we'll break down the full-cycle methodology, digital twins, and case studies of replacing imported equipment;

Why mining and processing projects turn into long-term construction

Building a mining and processing plant is one of the most complex and lengthy processes in industry. According to TAPP Group, traditional mining projects get dragged out for 3–5 years due to scattered contractors and outdated methods, and 30% of the budget is lost on rework (example: a coal plant whose estimate increased from 10 to 38 billion rubles).

The mining and processing industry has encountered a paradox:

• Gold miners are ramping up capacity (gold prices are hitting records) but face equipment shortages;

• Coal producers are losing margin (the sector’s loss in 2024 is 112.6 billion rubles) but are forced to modernize.

Typical problems faced by mining plants:

1. Broken cycle: geological exploration → design → construction.

Example: a coal plant, whose budget grew from 10 to 38 billion ₽ due to five contractor changes.

2. Outdated approaches: design institutes use “textbook” schemes from 50 years ago.

About 40% of the time is spent on approvals instead of practical work.

3. Sanctions pressure: delivering spare parts through third countries has tripled lead times, and equipment insurance has reached 15% of the cost.

Digital twins, AI, and parallel processes: a new formula for mining plants

The classic approach to building mining and processing plants is like a relay race, where each participant passes the baton to the next—and hopes it doesn’t get dropped. We proposed a different scenario: a single team overseeing the project from geological exploration to commissioning.

Let’s break down 4 key principles of full-cycle engineering that have proven effective

1. Vertical integration of processes:

   All stages — from geological exploration to commissioning — are handled by one team. Case: a plant with a capacity of 3 million tons of coal/year was implemented in 6 months instead of 4.5 years.

2. Digital twins instead of “paper” projects:

   Full digitalization of technological chains: automated collision checks reduce errors by 40%.

3. Turnkey equipment:

   Sanctions became a trigger for breakthrough solutions:

   • American high-frequency screen at “Vorkutaugol” that produced coal concentrate with about 20% moisture. TAPP’s development reduced it to 12% and increased output from 550 to 900 thousand tons.

   • Proprietary patented lines (for example, clay dewatering for a phosphate plant)

4. AI optimization:

   AI in design: choosing a technological chain in 2–3 days instead of 3 weeks. Plans: partially AI-controlled autonomous plants by 2030.

Results: figures instead of promises

Qualitative changes:

• Document flow reduced by 76%;

• Operators switched from manual control to analytics (73% of working time);

• The predictive maintenance system prevents 9 out of 10 accidents.

Perspectives: from earth mines to lunar bases

The mining industry stands on the verge of a technological revolution. If five years ago autonomous mines seemed like science fiction, by 2027 they’ll become an industry standard. Where is the industry heading, and what technologies will define its development?

1. Full automation: people-free mines

   By 2030, TAPP Group plans to implement the “manless mine” concept, where all processes — from drilling to ore transportation — will be managed by artificial intelligence. We’re not replacing people — we’re moving them from dangerous mines to control centers where they analyze data instead of risking their lives.

   • Unmanned haul trucks cut logistics costs by 40%.

   • Drones with lidar scanning create 3D maps of deposits with 10 cm accuracy.

   • Robotic drilling rigs operate around the clock, increasing productivity by 25%.

2. Artificial intelligence in every process

   TAPP Group made a qualitative leap in the use of AI technologies, turning them from auxiliary tools into full-fledged control systems:

   • AI geologist cuts the time to find deposits from 2 years to 3 months.

   • Digital twins in real time adjust equipment parameters.

   • Predictive analytics warn of malfunctions 72 hours in advance.

3. Space mining: the next frontier

Our ideas can be used for extraterrestrial mining. If we can build mining and processing plants in 6 months on Earth, why not do it on the Moon?

Conclusion

The mining and processing industry can no longer afford the luxury of drawn-out construction projects. Sanctions and growing competition demand new approaches.

What will change the industry:

• Implementation times will be reduced by 4–6 times — digitization of cycles will allow mining and processing plants to be built in 8–12 months;

• Automation will cover 80% of processes — this will reduce costs by 20–30%;

• Space mining will become a reality.

Are you ready for AI to do your job in ten years? Share your opinion in the comments!