Post on 25-Jan-2017
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Intelligent MiningIntegrated Mine Planning and Operations
Rafal Walecki – Head of EMEA Delivery, Mining Solutions, ABB
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Challenges & HistoryOur visionABB’s Solution ComponentsHow it all fits together
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OUR VISION
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Challenges driving shareholders returns
Depleting Reserves
Export Tonnage
Inland Tonnage
Declining Grades
Prim
ary
Gra
de, %
1.5
1.4
1.3
1.2
1.1
0.9
Increasing Costs80
60
40
20
02000 2011
Consumables
Labor
EnergyOther
Source: Xstrata Copper
Ore grade quality is declining
Reserves are depleting in some
commodities. Assets and ore bodies are
becoming more complex.
Labor is more costly, energy costs are going up and the doing business in new markets puts
pressure on margins
The bottom line: how to continue to deliver high returns to shareholders
1980 2000 2020
2000 2015 2030
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Step-changes in mining technology
• Standardization of processes
• Mechanization means dramatic shifts in production capabilities
• Operation of equipment still requires human interaction
• Integrated modeling and planning for higher quality yield
• Greater visibility into parts of the value chain
• More detailed information coming from equipment and plant to enable remote mining
• More responsive demand and supply
• Higher level of automation driven by labor shortages and remote mining locations
• Limiting bottlenecks by adopting more continuous processes
• High levels of visibility across the value chain and between operations
Mechanization Automation Optimization
The mining industry has been through a number of technology ‘step-changes’ which
have driven dramatic increases in productivity. Research into mining technologies indicate
significant new technologies heralding the next era of mining productivity
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ABB Mining Vision Coverage
To drive fundamental change in the way a Mining Enterprise works, creating dramatic increases in
Health and Safety
Productivity
Predictability
Asset Availability
Energy Efficiency
Quality
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Mining Conveyer Asset Health
Temperature sensors detect overcurrent
condition on conveyor drive and create alarm
Control system slows belt speed to reduce
risk of an issue
Work order automatically raises a
parts requisition
Work order is sent to maintenance crew mobile devices and work is completed
Condition, inspection, and work combines for
a unified view of conveyer health and optimization of the
current maintenance programs
1 2 3
456
The old way: No information on upstream
downstream impact Cant prioritize significant data
volumes - manual Production, equipment and
other control systems not integrated
Work order scheduling in disparate systems
No optimization of assets
Value Proposition
Transform real-time and historical asset data into strategic insights on the health of your mission-critical assets.
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Mining Plant Operations Optimization
Advanced process control (APC) manages
reagent dosing and flow rates in real-time
(OT)
Geological model and real-time material
tracking provides short term feed
characteristic schedule to APC
Sales system monitors global index pricing for
products
Sales system periodically provides
relative pricing updates to APC
APC refines control set points to maximize returns for current feed material and
product pricing
On stream analyzers in plant reconcile actual
feed with model to further improve
predictability and optimization
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567
The old way: No information on relative
product pricing No information on feed
material Plant set points static Production, equipment and
other control systems not integrated
Value PropositionIncrease plant recovery and optimize product mix based on current pricing.
4
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SOLUTION COMPONENTS
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Solution Components
Plant ReportingMass BalancePlant Efficiency
Material Logistics & Blending
Inventory ManagementSales & Marketing
Enterpise Asset ManagementWork and Projects ManagementMaintenance Management System
Lab ManagementSample Tracking
QA/QC Quality
Geological ModelingMine Planning/SchedulingMine Operations
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Geoloigical Modeling & Mine Planning
Geology &Mine Planning
Other Geological Database
Geological Model Excavations Model
Production Scheduling Mine Design
Geological Database
Exp
lora
tion
Survey
Asset & Work Management Product Logistics & Sales
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Material Logistics and Sales
Mining Activities
Processing
Transportation
Top Soil Drilling Overburden Waste Dump Parting Removal Loading Hauling Reject Disposal Rehabilitation
ROM StockpilesHauling Processing Plant Product Stockpiles Load Products
Transporting Train Loading Ship LoadingPort StockpilesTrain UnloadingRail Head Stockpiles
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Mining Laboratory Management System (LIMS)
Q
B
L Lab Status
QA Flag
Budget / Actual
Sample
Analytical Result
Dispatch
S
AD
Legend
Assay Mgmt LabInstrument
Integration/Interface Layer
ABB CCLAS Modules
LabConfig.
Web Interface, Dashboards & Reporting
BIReporting
Rules User Forms
QA &SPC
ERPSystem
D A AS
DataAudit
SampleRegistrat’n
DataCapture& MDE
DataCalculat’n
Scripting
SampleTracking
LabMaint.
L
Invoice &Revenue
Task Automt’n
Consum-ables
Instr.Mgmt
Archive/Retrieve
A A
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Production Accounting
Management Systems (e.g. ERP)
Total production by period, KPIs, qualities, inventories
tons, volume, grade, moisture, hardness, penalty elements - transaction, shift, day, week, month
METAL ACCOUNTING BUSINESS PROCESS
Acquire
Validate
Authorize
Calculate
Report
Publish
Analyze
Audit
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Asset Management
Enable PAS 55 Standardize Asset Management practice
Mobile Workforce Management Manage assets from the point of inspection Automate field-based processes Optimize mobile workforce, including 3rd party contractors
Asset Management Paradigms for Critical Assets Manage in terms of both Risk and Criticality Location based asset management with GIS integration
Advanced Work Planning Closed-loop long and real-time work planning and scheduling
Materials Management Total asset visibility Financial fidelity of assets and improved inventory management
Enterprise Visibility Highly flexible, open analytics and reporting
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How it fits together – Complete Integration
PA MineScapeCCLAS
• Supply Chain Network Configuration
• Inventory & Stockpile Management• Material Tracking• Waste Dump Management• Outbound Logistics Scheduling• Blending to and Optimization• Port operations & Ship loading• Sales & Invoicing• Shipping documents• Supply & Demand Balancing• Contract Fulfilment & Management• Mining Data Reconciliation
• Transaction assays• Transport assays• Ship loading assays MineMarket
Laboratory Information Management System
Resource block model
Production Schedule
Pit/UG Surveys
Actual Production
Aggregated transactions
Daily stock balance
End of period survey
Reconciled transactions
• Sample ID• Transaction details
Block ID
Assay data
Moisture
Assay data
• Geological DB• Stratmodel• Block model• Opencut design• Underground
design• Ring design• Scheduling• Mine & pit survey• Dragline• Haul roads• Drill & blast
• Auto data acquisition• Auto data validation• Statistical validation• Data checks• Data sign-offs• Auditing• Cascading calculations• Check in – Check out• Statistical balancing• Data locking
(quarantined)• Data publishing
EllipseASSETS Asset Policy Capital Work Register Asset Develop Strategy Deploy Strategy Asset Analysis
WORK Create Plan Schedule Execute Complete Work Analysis
MATERIALS Requirements Source Materials Procure Use Materials Distribution Performance
Analysis
PEOPLE Maintain Organization Workforce Planning Organizational
Development Time & Attendance Pay & Benefits HSSRE
FINANCIAL Financial Model Accounts Payable Accounts Receivable Fixed Assets General Ledger Performance & Compliance
Production S
chedule
Equipm
ent Data
Equip. Availability
Production by period
Quality data
Inventories
Financial & K
PI
Reserves
• Production by period• Stock balance• Equipment delays• Equipment usage• Shipment actuals• Invoicing details
• Budget & Forecasts• Production plans• Contracts details• Shipment schedule• Equipment master
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How it fits together - Operations Visibility
VP Health, Safety & Compliance
VP OPS
PERFORMANCE
CFOCIO
VPProcurement
KW-hours/ton
Delay penalties per month
Equipment-incidents /
month
Ship over-under load/month
Drill-blast cost/ton
Reagents/ton
Fuel/ton
Metric per Unit-Product-
Produced
Dig rate by shovel
DilutionAvailability
Throughput
Shipping queue length
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How it fits together - Intelligent Operation
Data Processing and Analytics
Subject Matter Workbench
Geology & Mine Planing Product Logistics
Equipment
Performance
Work Parameters
Technical Specifications
Sensors
SCADA
SCAD
A
Feedback Information
Volume
Mass
Quality
Feed
back
ConditionalMonitoring
Operations Control Center
Info
rmati
on
D
ecisi
ons
Results
Historian
Enterprise Data Sources
EAM
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How it fits together - One Control Room
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FIND OUT MORE
Visit www.abb.com/enterprise-software
Email info.PGES@abb.com