MINE HOISTS
ABB's multi level hoist optimisation
With demand for commodities spiking worldwide, the onus is on mining
operators to improve the performance of existing assets – including
critical equipment such as the hoist and the other devices and processes
it interacts with – in an effort to increase the production rate of their
operations, reduce the cost per ton produced, and extend the lifespan of
mine sites (or establish new ones).
Oswald Deuchar, Global Product Group Manager, Underground Mining
at ABB, told IM: “Employed to safely transport personnel, equipment and
material underground, as well as ore to the surface, mine hoist
maintenance requires both electrical and mechanical engineering skills.
Hoists handle heavy human and material payloads at high speeds,
meaning any critical failure can have severe consequences. Reliability and
availability for optimum production and safety is key. Hyper-connected,
CO 2-free and autonomous, the mine of the future will be powered and
informed by digital technologies, and that vision extends to all facets of
operations, including the mine hoist.”
ABB believes the answer to improving productivity and safety while
reducing costly system shutdowns lies in increased automation and data
integration. ABB Ability™ MineOptimize integrates system solutions and
services, and connects and optimises equipment of mines, mineral
processing plants or enterprises during their entire lifecycle, from design
and build to operation and service.
Deuchar adds: "Against a backdrop of rapid advances and innovations
in digitalisation and automation technologies, future mine operations will
incorporate hoist solutions that enable users to automatically gather and
analyse data to expedite identification of issues that need prioritising,
thus improving performance."
Using automatic data collection and analysis, Deuchar says that
connected hoist systems can identify potential problems before they
occur, meaning necessary actions can be taken at the right time. This
reduces costly, unplanned stoppages, and improves the overall
availability and availability of hoist equipment. By employing the latest
version of ABB Ability™ Performance Optimization, operators can adopt a
holistic, digital approach to improving the productivity and safety of mine
hoists simultaneously.
He says that part of the ABB Ability™ suite of digital solutions
Performance Optimization is a remote-enabled, software-assisted service
that monitors mine hoists 24/7 to improve performance. "Data on key
parameters is automatically collected, monitored and analysed to
generate actionable insights that increase production performance,
identify safety hazards, and optimise maintenance scheduling. The
service analyses the safety brake system, the hoist supervision and the
normal hoist operation to ensure safe and reliable operation, connecting
customers to experts for further evaluation and troubleshooting through
the ABB Ability™ Collaborative Operations Center in Västerås, Sweden."
ABB’s digital solution is split into two distinct levels. At Level 1, the
Hoist Performance Fingerprint consultancy service assesses, inspects and
tests the entire system by analysing data at a set point in time. The
electrical and mechanical service for ABB and third-party equipment is
performed simultaneously on-site. Level 2 involves ABB Ability™
Performance Optimization for hoists, where critical data is collected and
analysed round the clock and problem resolution actions are generated
and communicated to the personnel on-site in order to identify and to
rectify issues before they become problematic.
Hidden failures and regulatory compliance
A modern mine hoist comprises of sophisticated, finely tuned
technologies including variable speed drives; electric motors; electrical
Part of the ABB Ability™ suite of digital solutions, Performance
Optimization is a remote-enabled, software-assisted service that
monitors mine hoists 24/7 to improve performance
networks; rope and shaft equipment protection and systems for process
control; safety monitoring; controlled braking; electronic speed; and
distance protection.
Deuchar comments: "Factors such as human inputs and excessive wear
mean hoists consume more energy and become less efficient over time,
increasing the likelihood of ‘hidden failures’ that drive up both capital and
maintenance expenditure, and thus the mine’s cost per tonne, one of the
most vital parameters. Mine hoists are in constant use, meaning there is a
limited window for maintenance, particularly on end-of-line protection
equipment. Engineers must display a deep knowledge and understanding
of the entire hoist, as routine maintenance can focus on individual
mechanical or electrical components and overlook the broader picture.
Mining operators and their service providers must ensure hoist safety and
performance complies with local laws and regulations in every
operational jurisdiction."
Innovation in action: Finland and Canada
Friction hoists use tail ropes to balance the rope weight, so only the
weight of the payload requires motor power. Today’s modern friction
hoists can carry up to 65,000 kg in mines up to 2,000 m deep. ABB has
previously announced that is has been commissioned to install and bring
online a friction-type production hoist with 2.5 MW of motor power in a
mine shaft over 1 km deep at Agnico Eagle's Kittila gold mine in Finland.
ABB has said it will also deliver a 1.2 MW single drum personnel hoist as
well as online remote support services for real-time condition monitoring
using ABB Ability™ Performance Optimization for hoists, ensuring
optimum availability. The personnel and production hoists at the gold
mine will be installed in 2020–21, with the processing capacity of the
mine's concentrating plant increasing from the current 1.6 Mt to 2 Mt per
year.
In Canada, ABB is a longstanding supplier to the potash industry. This
includes a recent contract to supply the production hoist and all related
mechanical and electrical systems to Mosaic's new K3 potash mine in
Saskatchewan. A high-power, low-speed synchronous motor and Safety
Integrity Level 3 rated safety brake system will provide optimum safety,
security and reliability for the friction hoist operation. At 15,800 kW, this
will be the largest mine hoist electrical powertrain in North America. ABB
will also supply the hoist control system, power infrastructure and
automation equipment, plus engineering, turnkey installation and
commissioning services. The new hoist is scheduled for commissioning in
2021.
84 International Mining | JULY/AUGUST 2020