PROCESS CONTROL
indurad technology solution advanced HMI / SCADA visualisation for advanced plant control
process control system and SCADA , where we assist with a global network of system integrators using Rockwell , Siemens and Schneider PLC , MES and SCADA systems beyond advanced views via Qt-based graphical engines with 4K HDMI output for remote operation centres or HTML5 web output on premise within the IT or OT network .”
Mining is full of uncertainties and variance . indurad argues that while these cannot be eliminated – they can be significantly managed and mitigated . The indurad technology is focusing on this stack . “ Our iCrusher allows the identification of oversize , our iStockpile5D allows monitoring and homogenisation of product quality and reduction of segregation . The maritime industry has been pioneering in the use of radar for adverse environmental conditions – indurad brought this success to mining allowing machine vision under dust , water suppression , fog and snow . iApron and iBelt allow reduction of spillage and avoidance of blocked chutes as well as lifetime extension of feeders . Finally , teleremote operation and full automation with iStacker and iReclaimer allow management of the human factor .”
Sam Walsh , the former CEO of Rio Tinto has been bringing the Six Sigma approach into mining . His guiding principle has been ‘ there will be latent capacity there .’ At at recent St Barbara lunch of the Western Australian Mining Club he emphasised : “ There will the things that don ’ t run smoothly . You can work through with focus . So there is variation in mining . And there is an opportunity to apply the discipline of Six Sigma to mining .”
When loading wagons with iron ore there is significant variation in the outload process , both by tonnes per car and by loading time . indurad iLoadout has been proven to add one tonne more ore per car , while reducing the number of overloads at the same time , resulting as well in more energy efficient haulage and compliant trains plus mitigating the risk of bogie-bias and derailment risk . indurad applies radar machine vision to target the reduction of variation with end-to-end from mine-to-market , split in two value chains . The ‘ mine-plant-product ’ process is present at all mining operations , whereby indurad is focusing on the dry process plant of large copper , gold , bauxite , salt , iron ore and coal operations , however , also at smaller operations focusing on critical minerals like nickel and lithium . The rail outload process is very focused on iron ore , salt and coal . The nature of a connected system eliminating downtime and adding productivity during uptime typically results in double digit value opportunities .
Digital twins at Quellaveco
Anglo American says it has implemented cuttingedge technology at the Quellaveco copper mine in Peru with which it is possible to create a virtual replica that simulates everything that happens in its process plant , and with this , digital mining specialists can carry out predictive tests that help reduce security risks , optimise the use of resources and improve the performance of production teams .
The digital twins allow virtual replicas of the equipment and infrastructure to be made , displaying information on technical characteristics and operation utilising IoT , with the same data as that provided by the sensors installed in the mine . The digital twins are controlled from the Integrated Operations Center ( CIO ), which is the brain of Quellaveco . There are twins of the grinding system , flotation , tailings management , water control , electrical system , among others . These are
The integrated Siemens COMOS software solution makes it possible to consolidate automation data from the control systems of different providers
learning and provide recommendations to avoid failures in the equipment or real processes , optimising costs and time , through simulations of the different processes , using artificial intelligence ( AI ).
“ Digital twins not only allow us to have better performance , but they increase safety by reducing error rates , which means a new standard of efficiency in the mining industry ,” says Cinthya Lozano , Superintendent of the Integrated Operations Center of Anglo American . “ For example , we can place a parameter in a pump and see how it behaves . If it doesn ’ t work properly , we change these parameters as many times as necessary , and when we have the correct data we just take it to the real world ,” she adds .
Quellaveco is one of the first mines to implement digital twin technology to improve efficiency and safety in its mineral processing plant , taking advantage of the connectivity and sensorisation that have made it the first 100 % digital mine in Peru .
Underpinning the Anglo American Quellaveco digital twin is the COMOS platform from Siemens which integrates Siemens ’ own process control system Simatic PCS-7 , which for example controls the gearless driven conveyors and grinding circuit , together with other systems . The integrated COMOS software solution makes it possible to consolidate automation data from the control systems of different providers .
Siemens states : “ It guarantees the optimal collaboration , continuity , and consistency of all the disciplines involved in plant engineering and operation . The system accomplishes this by consolidating a variety of sources . Using the automation digital twin of the COMOS software solution , automation data can be read out of the process control system and imported to COMOS to be graphically displayed , consolidated , and made available for further engineering . COMOS uses this data to support the creation of the plant ’ s digital twin , a fast and reliable migration , and updates to the process control system – all with one single solution .”
IM
14 International Mining | JANUARY 2023