Smart control and automated regulation in the coal industry: transforming industrial process systems in the digital age

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