PROCESS CONTROL
ABB overview of total plant electrification
monitoring and remote control . All this has come together in a complete offering to the mining sector .
Optimising power distribution
Supplying and managing power for critical mine
processes means integrating technology solutions vertically and horizontally throughout the entire enterprise , as well as collaboration between key industry stakeholders , as Mehrzad Ashnagaran , Global Product Line Manager Electrification at ABB , explained to IM .
“ Mines are typically large , complex , assetheavy operations . More and more are going to be located in remote and inhospitable areas far from established infrastructure . As such , they constitute a high-stakes and high-risk investment . Engaging with a trusted supplier of key systems , products and services early in the project life cycle significantly de-risks process plant development , leading to considerable CAPEX and OPEX savings , enhanced electrification , automation and plant efficiency , and reduced energy use and emissions .”
He adds that detailed planning and execution at the project design stage is key to optimising power distribution that is fully integrated vertically in each mine section , and horizontally distributed from pit to port ; plus delivering customised power supply and management solutions for various mine processes ; and why collaboration can help to solve issues around power consumption and storage .
“ Process plant development requires a consumer-focused approach , however . By that I mean identifying which process areas in the mine need to be prioritised in terms of energy consumption and ensuring the distribution system is robust and flexible enough to supply that power 24-7 / 365 . Grinding systems or belt conveyor systems , for example , consume large amounts of power in some cases – while other process sections like flotation systems are less power-intensive , but still require continual supply . The onus is therefore on technology vendors such as ABB to develop customised power supply and management solutions that cater for the individual needs of all mine processes .”
ABB has various solutions to optimise entire power distribution and provide a conceptual design for entire electrification and automation system . For example , ABB has a specific multidrive solution for the belt system , for instance , which offers mine customers better efficiency and reduced CAPEX . Similarly , it offers premanufactured E-houses that are fully fit for purpose for mining harsh environment , complete with the correct IP , fire barrier and long lifecycle . In addition , power factor correction and harmonic filtering solutions are fitted in the different units connected to the system , maintaining power quality in the process area .
“ ABB ’ s MineOptimize platform not only helps to design the mine power system in most optimum way and provide most suitable technology but also helps personnel supervise , control , optimise and predict the behaviour of process plant power equipment and systems throughout the entire mine , maintaining a dynamic balance of power at all times , and maximising KPIs and operational targets .”
Now , Ashnagaran says that ABB Ability™ eMine™ is taking that one step further by vertically integrating electrification control and instrumentation solutions along the entire production chain , as well as horizontally integrating power distribution to all mine areas to give the customer a single process power solution for their entire enterprise , one that encompasses everything from rectifier service stations to electrification of the haul truck fleet and rapid-charging infrastructure such as the new eMine™ FastCharge system .
He states : “ Providing process power to mines requires developing and maintaining dedicated products based on electrical , automation and digital platforms . Just as important is engaging with stakeholders such as OEMs in order to facilitate new approaches to collaborative working and knowledgesharing . At ABB , we call this approach KTS , or ‘ key technical suppliers ’, whereby technology providers in the market work together to create solutions for the entire mine . An example is ABB ’ s collaboration with Liebherr and Hitachi to develop a zero-emission electric rigid dump truck that incorporates a customised on-board energy storage system .”
These types of partnerships – coupled with process plant power solutions designed to accelerate the transition from fossil fuels to renewable energy – he says will help ensure that mines throughout the world continue to receive the stable supply of clean power they require to function far into the future .
Reducing process variation indurad ’ s iStockpile4D™ is a radar machine vision ‘ Stockpile-as-a-Service ’ solution for ore , salt or coal stockpile management from ROM to product pile . The digital-reality is based on actual 3D radar scanning plus a next generation neutron generation elemental analyser exceeding mathematical modelling . It reduces product and process variation and the company says is unearthing significant multi-million dollar values in productivity and profitability . indurad was already a pioneer being part of RioTinto ’ s Mine of the Future program some 10 years ago with smart instrumentation and machine vision in mine outload optimisation . Today all 14 Rio Tinto Iron Ore ( RTIO ) mine sites in the Pilbara have been fitted with indurad technology , including an iStockpile4D and iLoadoutG5 solution at the flagship Gudai-Darri highly automated mine .
Reik Winkel , indurad Executive Officer told IM : “ indurad solutions are geometric measurement solutions feeding easy to digest data to the
12 International Mining | JANUARY 2023