PROCESS CONTROL triggers an alarm plus each incident is logged and investigated . The final piece will be better machine learning and AI within the APC to get further productivity wins especially when the ore nature changes . And this is already happening .”
It makes sense for mining too – in an oil and gas refinery or chemical plant there are digital performance gauges on nearly all of the equipment . In a mineral processing plant , apart from maybe electrical boxes , there is very little visible data in the plant whether on the mills , cyclones or wherever . All this data is only visible in the control room anyway so why not automate its operation ? It is also about reliability – making sure everything is maintained during planned shutdowns and if possible to never have an unplanned maintenance incident . With thickeners , where you have a low water supply , the APC will make sure the thickeners can still operate without torque limits etc being exceeded .
Today , Codelco ’ s approach is still a world leader , with most of its operations being operated remotely , not just monitored remotely . Others have followed – BHP is now operating Escondida from a similar facility in Santiago that opened in 2019 and which has both Honeywell and Emerson technology and its Spence Growth Option ( SGO ) ROC will be its most advanced in the world , which is to use Honeywell systems .
The Codelco set-up includes incorporate remote operation and remote monitoring centres equipped with video transmission equipment , video IP phones and a large-scale display wall ; testing , development and training laboratories ; and meeting , training and video conferencing facilities .
Honeywell says the ROC facilities used data analytics , predictive maintenance and Honeywell Connected Plant expertise to deliver radically improved production , productivity and increased revenues at Codelco ’ s plants . “ Operators can see production environments clearly through cameras and high-resolution screens , and are better coordinated since they can work together in the same room . Codelco is also able to achieve the full automation of its Advanced Process Control ( APC ) systems , and to manage and exploit large volumes of data to improve production performance . Meanwhile , operations staff are alerted in real time to potential problems , and can modify processes to prevent the loss of continuity .” The Operations Centres have helped Codelco fine-tune production , improve the use and availability of equipment and systems , reduce costs and increase the productivity of its teams .
There are actually eight listed major Codelco Operations Centre functions : Remote Support ; Ministro Hales Remote Operations ; Competency Management ; Connected Assets ; Application Development ; Lifecycle Support ; Advanced Process Control Support ; and Process Support .
There are three business drivers for Codelco ’ s Remote Support Centre function , through which cross-functional specialists support processes , advanced control applications , DCS and
communications at all of Codelco ’ s plants : n Sustain automation benefits over time n Overcome the lack of on-site specialists n Reduce downtime and improve operational continuity Connected to the plants through a secure private network , the Remote Support Centre provides centralised access to multi-plant process information and automation resources , plus services to follow-up processes , support plant operators , identify improvement opportunities and facilitate changes in operational practices to sustain automation benefits .
The ROCs include the Honeywell Experion ® Process Knowledge System platform ; intuitive Experion Orion consoles ; an alarm management system ; control operations for SAG , grinding , flotation and roasting processes ; Digital Video Manager ; and remote radio communications .
Honeywell has helped Codelco integrate processes , information and decision making – creating a connected production environment that ’ s delivering $ 45 million in incremental revenue annually through improved production quality and productivity for MMH , and is now doing so for other sites .
Changes in manufacturing process dynamics , technology obsolescence and operational practices can cause control strategies to lose their effectiveness over time unless their performance is periodically evaluated and re-tuned to process conditions . The Codelco APC Support function helps identify ongoing improvements to Codelco ’ s control strategy and operator performance . Control applications must be set by operators according to process conditions . APC Support specialists help operators deal with abnormal situations and provide guidance to stabilise processes .
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Due diligence
JANUARY 2021 | International Mining 21