For the First Time in Iran’s Mining Industry: Design, Development, and Deployment of AI-Based Intelligent Behavior Monitoring and Anti-Collision Systems at Sangan Iron Ore Complex

As part of efforts to enhance operational safety and move toward data-driven preventive safety management, six intelligent systems for operator behavior monitoring and heavy equipment anti-collision warnings were designed, installed, and commissioned at the Sangan Iron Ore Complex—the first deployment of its kind in Iran’s mining industry.

Engineer Jahantab, HSE Manager of the Sangan Iron Ore Complex, highlighted the importance of using advanced technologies in mine safety:

“Today, traditional and reactive approaches to safety management are no longer sufficient to address the complexity of mining operations. The implementation of these systems represents an important step in the transition from reactive safety management to data-driven preventive management. These technologies can play an effective role in reducing operational risks and preventing accidents.”

He added that these systems enable real-time monitoring of operators and equipment, allowing for the identification of high-risk behaviors, timely warnings, and continuous analysis of safety indicators. This provides the HSE department with valuable support for faster, more accurate, and more intelligent decision-making.

Dr. Abdolhadi, CEO of Nasir Simulator Tech. Co. and the designer and project lead, also explained the details of the project:

“This project was designed with the aim of developing intelligent safety infrastructure for the country's mining industry. It includes an integrated suite of systems for behavior monitoring, fatigue management, and equipment collision warnings, providing managers with the ability to analyze operational data and access specialized management dashboards.”

He further explained that the systems deployed at the Sangan Iron Ore Complex include:

• Intelligent fatigue management systems for drivers and equipment operators
• Anti-Collision warning systems for mining equipment
• Operator behavior monitoring and analysis systems
• A system for detecting high-risk behaviors during dump truck operations
• A data analytics platform and HSE management reporting system

Dr. Abdolhadi emphasized the role of emerging technologies in the future of the mining industry, stating that the use of artificial intelligence in mine safety has the potential to transform the future of safety management.

He added that this project can serve as a successful model for the development of smart mines, the reduction of human-related incidents, and the improvement of operational productivity across the country.

The Sangan Iron Ore Complex, one of the country's largest mining hubs, has in recent years pursued the development of advanced technologies, digital transformation, and the intelligentization of operational processes as key strategic priorities.