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The future is around the corner: Nornickel innovation investment

Over the past three years, Nornickel has invested more than USD 10 bn in new technologies and plans to invest another USD 3 bn in 2024. The most notable projects include Sulphur Programme Stage I, a digital plant twin, automation at mines, and green energy R&D. The test will help you learn about the company’s latest achievements.

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Kola MMC is testing the unique Oreflow system. What area of artificial intelligence does it use?
Kola MMC’s Severny mine is testing an innovative digital system, Oreflow. It monitors ore haulage and feedstock quality using computer vision. Cameras are installed in each ore pass. In these locations, rock is fed by gravity from the extraction site to the transport level.

Images are processed by AI on a 24/7 basis using a preset algorithm. An operator can view the image online or navigate the archive at the end of the shift. All deviations are marked in certain colors. The AI system records the water content of ore and how it sticks to equipment, and indicates if vehicles are underloaded or loaded with oversized grade.

The AI-based monitoring helps improve the feedstock quality, save the company’s money, and extends the service life of equipment and utilities.
Kola MMC’s Severny mine is testing an innovative digital system, Oreflow. It monitors ore haulage and feedstock quality using computer vision. Cameras are installed in each ore pass. In these locations, rock is fed by gravity from the extraction site to the transport level.

Images are processed by AI on a 24/7 basis using a preset algorithm. An operator can view the image online or navigate the archive at the end of the shift. All deviations are marked in certain colors. The AI system records the water content of ore and how it sticks to equipment, and indicates if vehicles are underloaded or loaded with oversized grade.

The AI-based monitoring helps improve the feedstock quality, save the company’s money, and extends the service life of equipment and utilities.
Kola MMC’s Severny mine is testing an innovative digital system, Oreflow. It monitors ore haulage and feedstock quality using computer vision. Cameras are installed in each ore pass. In these locations, rock is fed by gravity from the extraction site to the transport level.

Images are processed by AI on a 24/7 basis using a preset algorithm. An operator can view the image online or navigate the archive at the end of the shift. All deviations are marked in certain colors. The AI system records the water content of ore and how it sticks to equipment, and indicates if vehicles are underloaded or loaded with oversized grade.

The AI-based monitoring helps improve the feedstock quality, save the company’s money, and extends the service life of equipment and utilities.
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Which palladium compound does Nornickel propose using to increase solar energy efficiency?
Only 20% of solar energy is converted into electricity, meaning that solar potential is not fully exploited. Nornickel is the world’s largest supplier of palladium which could help solve this problem.

Scientists from the Siberian University teamed up with the Royal Institute of Technology in Stockholm to discover a new compound, Palladium Diselenide. It has a higher light absorption than silicon currently used in solar panels.

The company is also doing research on the use of palladium in hydrogen energy. In total, the company is designing over a dozen innovative Pd-based processes.
Only 20% of solar energy is converted into electricity, meaning that solar potential is not fully exploited. Nornickel is the world’s largest supplier of palladium which could help solve this problem.

Scientists from the Siberian University teamed up with the Royal Institute of Technology in Stockholm to discover a new compound, Palladium Diselenide. It has a higher light absorption than silicon currently used in solar panels.

The company is also doing research on the use of palladium in hydrogen energy. In total, the company is designing over a dozen innovative Pd-based processes.
Only 20% of solar energy is converted into electricity, meaning that solar potential is not fully exploited. Nornickel is the world’s largest supplier of palladium which could help solve this problem.

Scientists from the Siberian University teamed up with the Royal Institute of Technology in Stockholm to discover a new compound, Palladium Diselenide. It has a higher light absorption than silicon currently used in solar panels.

The company is also doing research on the use of palladium in hydrogen energy. In total, the company is designing over a dozen innovative Pd-based processes.
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Kola MMC’s electrolysis shop uses 80 steel tanks for solution mixing. To prevent steel corrosion, the tanks are coated with fiber reinforced plastic (FRP) from the inside. Where is it made?
Until recently, resin for tank coating was sourced overseas. Once supply chains were disrupted, Nornickel sent samples of imported resin to a plant in Yaroslavl. They studied the chemical composition and properties, and established an import-substituting production process.

Russian-made resin is not inferior to the best foreign counterparts, and is now way cheaper and faster. The old resin at the Kola MMC’s nickel electrolysis shop is now being removed and replaced by the new resin. This will protect equipment from corrosion and extend the life of the tanks.
Until recently, resin for tank coating was sourced overseas. Once supply chains were disrupted, Nornickel sent samples of imported resin to a plant in Yaroslavl. They studied the chemical composition and properties, and established an import-substituting production process.

Russian-made resin is not inferior to the best foreign counterparts, and is now way cheaper and faster. The old resin at the Kola MMC’s nickel electrolysis shop is now being removed and replaced by the new resin. This will protect equipment from corrosion and extend the life of the tanks.
Until recently, resin for tank coating was sourced overseas. Once supply chains were disrupted, Nornickel sent samples of imported resin to a plant in Yaroslavl. They studied the chemical composition and properties, and established an import-substituting production process.

Russian-made resin is not inferior to the best foreign counterparts, and is now way cheaper and faster. The old resin at the Kola MMC’s nickel electrolysis shop is now being removed and replaced by the new resin. This will protect equipment from corrosion and extend the life of the tanks.
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What place will Russia take in the world in terms of lithium production with the start of Kolmozerskoye deposit development by Norilsk Nickel and Rosatom?
Lithium is the primary raw material used in the production of batteries and an essential element for clean energy development. It is also used in glass, ceramics, petrochemical, and medical and nuclear industries. The world’s mine production of lithium was 130,000 metric tonnes in 2022.

The demand for lithium is expected to increase tenfold by 2030. The Kolmozerskoye deposit holds more than 500 thousand tonnes of lithium, which is however hard to extract. The concentration of lithium in the rock is about 1.5%, which means production will require a multi-step beneficiation process: high-temperature roasting and leaching.

An alternative process is sulfuric acid technology which permits ca. 90% lithium recovery as lithium hydroxide or carbonate. Scientists from the I.V. Tananaev Institute of Chemistry and Technology of Rare Elements and Mineral Raw Materials of the Russian Academy of Sciences Kola Scientific Centre have enhanced the process. Lithium recovery from the Kolmozerskoye deposit will reach 98%, with Cesium and Rubidium extracted as by-products.

The process requires large quantities of sulphuric acid, which can be supplied by Kola MMC in Monchegorsk. The first marketable product is expected in 2026-2027.
Lithium is the primary raw material used in the production of batteries and an essential element for clean energy development. It is also used in glass, ceramics, petrochemical, and medical and nuclear industries. The world’s mine production of lithium was 130,000 metric tonnes in 2022.

The demand for lithium is expected to increase tenfold by 2030. The Kolmozerskoye deposit holds more than 500 thousand tonnes of lithium, which is however hard to extract. The concentration of lithium in the rock is about 1.5%, which means production will require a multi-step beneficiation process: high-temperature roasting and leaching.

An alternative process is sulfuric acid technology which permits ca. 90% lithium recovery as lithium hydroxide or carbonate. Scientists from the I.V. Tananaev Institute of Chemistry and Technology of Rare Elements and Mineral Raw Materials of the Russian Academy of Sciences Kola Scientific Centre have enhanced the process. Lithium recovery from the Kolmozerskoye deposit will reach 98%, with Cesium and Rubidium extracted as by-products.

The process requires large quantities of sulphuric acid, which can be supplied by Kola MMC in Monchegorsk. The first marketable product is expected in 2026-2027.
Lithium is the primary raw material used in the production of batteries and an essential element for clean energy development. It is also used in glass, ceramics, petrochemical, and medical and nuclear industries. The world’s mine production of lithium was 130,000 metric tonnes in 2022.

The demand for lithium is expected to increase tenfold by 2030. The Kolmozerskoye deposit holds more than 500 thousand tonnes of lithium, which is however hard to extract. The concentration of lithium in the rock is about 1.5%, which means production will require a multi-step beneficiation process: high-temperature roasting and leaching.

An alternative process is sulfuric acid technology which permits ca. 90% lithium recovery as lithium hydroxide or carbonate. Scientists from the I.V. Tananaev Institute of Chemistry and Technology of Rare Elements and Mineral Raw Materials of the Russian Academy of Sciences Kola Scientific Centre have enhanced the process. Lithium recovery from the Kolmozerskoye deposit will reach 98%, with Cesium and Rubidium extracted as by-products.

The process requires large quantities of sulphuric acid, which can be supplied by Kola MMC in Monchegorsk. The first marketable product is expected in 2026-2027.
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What innovative equipment has been developed and manufactured at Nornickel’s request for the Copper Plant?
Nornickel has procured 52 exoskeletons for the Copper Plant, custom developed for the company.

Copper electrolysis shop workers are very vulnerable to occupational back pain from hard physical labour and difficult working conditions. During the shift, people lift and carry anode remnants, or scrap, weighing up to 50 kg. This job is much easier with an exoskeleton.

The innovative device looks like athletic equipment and weighs about 2 kg. In February 2024, employees underwent training at the plant. They were shown how to use, adjust and service the exoskeleton. It felt very strange at first working in an exoskeleton for different motion mechanics. But workers became used to it and appreciated the capabilities of a new assistant.
Nornickel has procured 52 exoskeletons for the Copper Plant, custom developed for the company.

Copper electrolysis shop workers are very vulnerable to occupational back pain from hard physical labour and difficult working conditions. During the shift, people lift and carry anode remnants, or scrap, weighing up to 50 kg. This job is much easier with an exoskeleton.

The innovative device looks like athletic equipment and weighs about 2 kg. In February 2024, employees underwent training at the plant. They were shown how to use, adjust and service the exoskeleton. It felt very strange at first working in an exoskeleton for different motion mechanics. But workers became used to it and appreciated the capabilities of a new assistant.
Nornickel has procured 52 exoskeletons for the Copper Plant, custom developed for the company.

Copper electrolysis shop workers are very vulnerable to occupational back pain from hard physical labour and difficult working conditions. During the shift, people lift and carry anode remnants, or scrap, weighing up to 50 kg. This job is much easier with an exoskeleton.

The innovative device looks like athletic equipment and weighs about 2 kg. In February 2024, employees underwent training at the plant. They were shown how to use, adjust and service the exoskeleton. It felt very strange at first working in an exoskeleton for different motion mechanics. But workers became used to it and appreciated the capabilities of a new assistant.
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Nornickel was the first in Russia to use which major process in its emission monitoring system?
Nornickel’s Predictive Emission Monitoring System (PEMS) is composed of several steps. At step 1, data is collected from a number of sources:
  • raw materials laboratory database: data on quality, chemical composition and other parameters;
  • equipment: temperature, pressure, flow rate and other parameters of current production processes;
  • weather forecasts: wind direction and strength, humidity, temperature, pressure.
The data is then fed to the digital twin process. Using the mathematical, physics and chemical equations and neural models, operation of a particular production chain is described in its entirety. System outputs include data on the quantity of gas and emissions concentration and instant response to any changes in the raw material or process.
Nornickel’s Predictive Emission Monitoring System (PEMS) is composed of several steps. At step 1, data is collected from a number of sources:
  • raw materials laboratory database: data on quality, chemical composition and other parameters;
  • equipment: temperature, pressure, flow rate and other parameters of current production processes;
  • weather forecasts: wind direction and strength, humidity, temperature, pressure.
The data is then fed to the digital twin process. Using the mathematical, physics and chemical equations and neural models, operation of a particular production chain is described in its entirety. System outputs include data on the quantity of gas and emissions concentration and instant response to any changes in the raw material or process.
Nornickel’s Predictive Emission Monitoring System (PEMS) is composed of several steps. At step 1, data is collected from a number of sources:
  • raw materials laboratory database: data on quality, chemical composition and other parameters;
  • equipment: temperature, pressure, flow rate and other parameters of current production processes;
  • weather forecasts: wind direction and strength, humidity, temperature, pressure.
The data is then fed to the digital twin process. Using the mathematical, physics and chemical equations and neural models, operation of a particular production chain is described in its entirety. System outputs include data on the quantity of gas and emissions concentration and instant response to any changes in the raw material or process.
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What is the purpose of the Anti-Collision system used at Nornickel?
People in large mining and metallurgical operations work underground in poorly lit environments, close to heavy machinery. To reduce injuries, Nornickel is implementing the Anti-Collision system that uses a thermal imager and neural network models. Whenever a person appears within a 7m radius of the equipment, the system activates braking. Another major safety project is laser projections near cranes and conveyors.
People in large mining and metallurgical operations work underground in poorly lit environments, close to heavy machinery. To reduce injuries, Nornickel is implementing the Anti-Collision system that uses a thermal imager and neural network models. Whenever a person appears within a 7m radius of the equipment, the system activates braking. Another major safety project is laser projections near cranes and conveyors.
People in large mining and metallurgical operations work underground in poorly lit environments, close to heavy machinery. To reduce injuries, Nornickel is implementing the Anti-Collision system that uses a thermal imager and neural network models. Whenever a person appears within a 7m radius of the equipment, the system activates braking. Another major safety project is laser projections near cranes and conveyors.
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Which product of the IMAKE Young Inventors League won second place at the 2023 IYIA international competition in Indonesia?
In the fall of 2023, the IYIA 2023 international competition was held in Bali, Indonesia. Participants included Dinara Faradzheva from Chita and Victoria Ilchenko from Norilsk, members of the IMAKE League of Inventors. In the competition, they presented the ECO Bear mobile waste collection and sorting project. A robotized bear-eared bin travels a specific path, makes sounds and shows videos to attract attention.

The League of Young Inventors has been organised by Nornickel under its World of New Opportunities charity programme. The project is designed for school students from 10 to 17 years old who live locations where the company has operations. They showcase their ideas for the League’s competition. The best ideas are brought to life. Some even receive international recognition.
In the fall of 2023, the IYIA 2023 international competition was held in Bali, Indonesia. Participants included Dinara Faradzheva from Chita and Victoria Ilchenko from Norilsk, members of the IMAKE League of Inventors. In the competition, they presented the ECO Bear mobile waste collection and sorting project. A robotized bear-eared bin travels a specific path, makes sounds and shows videos to attract attention.

The League of Young Inventors has been organised by Nornickel under its World of New Opportunities charity programme. The project is designed for school students from 10 to 17 years old who live locations where the company has operations. They showcase their ideas for the League’s competition. The best ideas are brought to life. Some even receive international recognition.
In the fall of 2023, the IYIA 2023 international competition was held in Bali, Indonesia. Participants included Dinara Faradzheva from Chita and Victoria Ilchenko from Norilsk, members of the IMAKE League of Inventors. In the competition, they presented the ECO Bear mobile waste collection and sorting project. A robotized bear-eared bin travels a specific path, makes sounds and shows videos to attract attention.

The League of Young Inventors has been organised by Nornickel under its World of New Opportunities charity programme. The project is designed for school students from 10 to 17 years old who live locations where the company has operations. They showcase their ideas for the League’s competition. The best ideas are brought to life. Some even receive international recognition.
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How many shopfloor workers and specialists were involved in the construction of the Sulphur Programme facilities at the Nadezhda Metallurgical Plant?
On 25 October 2023, Nornickel launched Phase I of Russia’s largest environmental project, the Sulphur Programme, at the Nadezhda Metallurgical Plant. The goal of the project is to drastically reduce sulphur dioxide emissions in Norilsk and improve air quality in the city.

Construction lasted more than three years. The main transport link for equipment delivery was the Northern Sea Route, with traffic enabled by icebreakers. To launch the programme, the company reconfigured part of its metallurgical operations, built a technological complex using a sophisticated sulphur dioxide utilization process and provided the required infrastructure.

As a result, Norilsk now has another plant the size of seven football fields and about 500 new jobs. Up to 4,000 workers and specialists and more than 400 units of special equipment were engaged 24/7 in the construction of Sulphur Programme facilities.
On 25 October 2023, Nornickel launched Phase I of Russia’s largest environmental project, the Sulphur Programme, at the Nadezhda Metallurgical Plant. The goal of the project is to drastically reduce sulphur dioxide emissions in Norilsk and improve air quality in the city.

Construction lasted more than three years. The main transport link for equipment delivery was the Northern Sea Route, with traffic enabled by icebreakers. To launch the programme, the company reconfigured part of its metallurgical operations, built a technological complex using a sophisticated sulphur dioxide utilization process and provided the required infrastructure.

As a result, Norilsk now has another plant the size of seven football fields and about 500 new jobs. Up to 4,000 workers and specialists and more than 400 units of special equipment were engaged 24/7 in the construction of Sulphur Programme facilities.
On 25 October 2023, Nornickel launched Phase I of Russia’s largest environmental project, the Sulphur Programme, at the Nadezhda Metallurgical Plant. The goal of the project is to drastically reduce sulphur dioxide emissions in Norilsk and improve air quality in the city.

Construction lasted more than three years. The main transport link for equipment delivery was the Northern Sea Route, with traffic enabled by icebreakers. To launch the programme, the company reconfigured part of its metallurgical operations, built a technological complex using a sophisticated sulphur dioxide utilization process and provided the required infrastructure.

As a result, Norilsk now has another plant the size of seven football fields and about 500 new jobs. Up to 4,000 workers and specialists and more than 400 units of special equipment were engaged 24/7 in the construction of Sulphur Programme facilities.
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Which gadget does an employee of the Skalisty mine use to control a drilling machine?
Over 2 km deep, Skalisty is the deepest mine in Eurasia. The mine bottom is operated by complex drilling machines with no people inside.

People stay 1,000m up to operate machines with a joystick as if playing a video game. This capability has been enabled through the project called “Automation of Face Travel and Precise Navigation of Self-Propelled Drilling Rigs”.

The system designed by Tomsk-based NTR has no analogues in the world. Navigation systems have been used in drilling rigs before; however, the new system features a much higher accuracy and uses different algorithms. Almost all equipment and devices are made in Russia.

The machine is operated from a remote control panel that is exactly the same as the control panel in the cab. Communication with the drilling rig is Internet-based. Like all other Nornickel’s mines, Skalisty is wired with miles of fibre-optic cable and equipped with hundreds of Wi-Fi access points. This enables real-time process monitoring.
Over 2 km deep, Skalisty is the deepest mine in Eurasia. The mine bottom is operated by complex drilling machines with no people inside.

People stay 1,000m up to operate machines with a joystick as if playing a video game. This capability has been enabled through the project called “Automation of Face Travel and Precise Navigation of Self-Propelled Drilling Rigs”.

The system designed by Tomsk-based NTR has no analogues in the world. Navigation systems have been used in drilling rigs before; however, the new system features a much higher accuracy and uses different algorithms. Almost all equipment and devices are made in Russia.

The machine is operated from a remote control panel that is exactly the same as the control panel in the cab. Communication with the drilling rig is Internet-based. Like all other Nornickel’s mines, Skalisty is wired with miles of fibre-optic cable and equipped with hundreds of Wi-Fi access points. This enables real-time process monitoring.
Over 2 km deep, Skalisty is the deepest mine in Eurasia. The mine bottom is operated by complex drilling machines with no people inside.

People stay 1,000m up to operate machines with a joystick as if playing a video game. This capability has been enabled through the project called “Automation of Face Travel and Precise Navigation of Self-Propelled Drilling Rigs”.

The system designed by Tomsk-based NTR has no analogues in the world. Navigation systems have been used in drilling rigs before; however, the new system features a much higher accuracy and uses different algorithms. Almost all equipment and devices are made in Russia.

The machine is operated from a remote control panel that is exactly the same as the control panel in the cab. Communication with the drilling rig is Internet-based. Like all other Nornickel’s mines, Skalisty is wired with miles of fibre-optic cable and equipped with hundreds of Wi-Fi access points. This enables real-time process monitoring.
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You do not believe in technical progress?
The dreams of 10 years ago are becoming today’s reality. You’ll definitely see that it’s true once you find out about Nornickel’s plans for production upgrades.
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Clearly, you are enthusiastic about innovations
We invite you learn more about how new technologies boost production efficiency.
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You can’t imagine your life without innovations
Even the bravest imagination is sometimes powerless against engineering ideas. Read an article about the Axioma system, which can predict harmful emissions and determine their dispersion.
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Photos by Nornickel, Shutterstock/FOTODOM
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