Michel Serres, ABB Canada, VP Mining Solutions NAM...
Transcript of Michel Serres, ABB Canada, VP Mining Solutions NAM...
MineOptimizeMichel Serres, ABB Canada, VP Mining Solutions NAM
An Automation Platform
© ABB Group
November 30, 2016 | Slide 2
The mining industry today The main challenge
• 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
• Reduce total ownership cost
• More responsive demand and supply
• Higher level of automation driven by
labor shortages and remote locations
• Limiting bottlenecks by adopting more
continuous processes
• High levels of visibility across the
value chain and between operations
Mechanization Automation Optimization
Five key
mining industry
requirements
• Productivity
• Safety
• Sustainability
• Reliability
• Environment
© ABB Group
November 30, 2016 | Slide 3
The mining industry future Attractive changes moving forward
Reduce cost, increase productivity, and safety by
remote monitoring, diagnostics and interventions
Move automation and electricity to where the
ore is extracted, minimize haulage, and transport
… people further away from processes … equipment closer to processes
Key features of future mining operations
Limited human presence in production area
Continuous production and mechanical excavation
Central control room
Continuous availability of ore, people, and equipment
The traditional way Remote monitoring of equipment, preventive maintenance
The traditional way Underground electricalsand autonomous equipment
… enabled by integrated operations from pit to port, fully automated, and remotely controlled
© ABB Group
November 30, 2016 | Slide 4
MineOptimize
System Engineering
Electrification & Automation
Power & Process Control
Collaborative Production Mgt.
The people, engineering expertise and
a century of knowledge and know-how
of electrification and process control in
mining
Integrated portfolio of products,
solutions and services to optimize
customer investment and process
productivity
Ability to Integrate third-party
application within an Automation
Platform, linked applications, data
correlation and data treatment.
Mining know-how
© ABB Group
November 30, 2016 | Slide 5
MineOptimizeIntegrated value chain from pit to port
Energy
Management
Wireless
Location Intelligence
Hoist, Ventilation,
Mine Planning
Dispatching &
Scheduling
Central Control
Room, ERP, CMSS
Grinding, GMD,
RMD, APC
Conveyor Belt
Control
Electrification
Solutions
Condition
Monitoring
Ship Load &
Unload Control
Flotation, APC,
Instrumentation
Stockyard
Control
Substation
Control
Drives
Solutions
High levels of visibility across operations
ABB Mining Solutions An Automation Platform approach...
https://www.youtube.com/user/abbmining
© ABB Group
November 30, 2016 | Slide 7
MineOptimize Automation SolutionOne power and process system approach
Integrated 800xA
process control and
power automation
Enable power &
process control and
integrated mine
operation
Improves information flow
and visibility across
organizational silos
Process and electrical
control software,
HMI displays
• Separate systems for different
parts, networks, servers,
teams, spare parts
The MineOptimize way
The traditional way
Integrated E&I device
monitoring and
configuration
Remote operation,
maintenance and data
access
Alarms and events,
audit trails
historical data,
trending
MineOptimize
© ABB Group
November 30, 2016 | Slide 8
MineOptimize Advanced Process ControlProcess optimization according to ore properties
Model predictive
control engine
integrated into control
system
More metal ore is
recovered
Higher equipment utilization,
increased recovery and
lower energy consumption
Real time ore
analyzer detects or
Mine Planning
application, changes
to ore grade
• No information on upstream
downstream impact
• Can’t prioritize significant data
volumes
The MineOptimize way
The traditional way
Predictive
adjustments made to
mining grinding
Plant react to ore
variability ahead of
time
Real time operations
reports changes in ore
properties
MineOptimize
© ABB Group
November 30, 2016 | Slide 9
MineOptimize Scheduling & DispatchingJust-in-time optimal process management
Personnel, mobile and
fix equipment
integrated into control
system
Operations team
working in the
optimum level
High degree of automation
and information access
enables safety and
production as per plan
Mine operators
schedule, dispatch
and track operations
in real time
• No information about the
location and status of
mobile/fixed equipment
• Cannot prioritize works plans
and loading sequences
The MineOptimize way
The traditional way
New task plans and
loading sequences
are calculated and
executed
Production analyses
and statistics can be
retrieved on-line
Mobile and fixed
equipment report local
conditions, task status
and location
MineOptimize
© ABB Group
November 30, 2016 | Slide 10
MineOptimize Condition MonitoringReact to asset condition in real time
Asset management
integrated into control
system
Reduces losses due
to equipment failure
Reduce maintenance costs
while improve equipment
reliability and reduce
unplanned shut-downs
Asset monitor detects
condition
• Reactive maintenance
• High operating costs
• Unexpected breakdown of
critical assets
• Catastrophic impact on
production targets
The MineOptimize way
The traditional way
Work order with site
maintenance crew is
raised automatically
Maintenance and
operation responds
ahead to reduce
failure risk
Predictive
maintenance alarm
is triggered
MineOptimize
© ABB Group
November 30, 2016 | Slide 11
MineOptimize Information ManagementMake goal-oriented decisions
Single information
platform integrated
into control system
Targets achieved
based on transparent
information
Make the right decisions
based on consolidated,
consistent and transparent
information
Automated data
collection,
consolidation and
calculation
• Manual data collection and
calculations
• Information available in
segregated documents
• Difficulty to identify differences
among multiple sources and
versions
The MineOptimize way
The traditional way
Consistent distribution
of information at the
plant and corporation
Information
empowering goal-
oriented decisions
Report process,
production, energy
and maintenance
KPIs
MineOptimize
Integrated Mining OperationImprove visibility, planning and real-time coordination
Improve operations
visibilityBy providing complete, accurate and timely data
Improve coordination
between functional silos
By providing better visibility and real-time management
system integration
Support improved
production rates and
throughput
By providing better planning capabilities to minimizes
bottlenecks
Reduce hazard
exposure
By removing people from hazardous environments
through better information and communications systems
Top benefits How we can help
Enterprise Software
ABB Automation Platform
ABB Mine Optimize
ABB Mining Solutions An Automation Platform approach...
ABB Confidential
© ABB Group
November 30, 2016 | Slide 14
The future of mining – extended automationBringing things, services and people together
Mine Smelter
Minerals / Metals
price volatility
Sales / Contracts
Corporate headquarters
Loading
and transport
Ore hoist
and feeding
Grinding Thickening FlotationCrushingDrilling,
charging
and blasting
Dryer Furnace ConverterFiltering
Ore feeder
Concentrate
transport
Electrification
Transmission
& Distribution
E-houses MCC &
Drives
Concentrator
ABB Mining SolutionsSolution Integration
Slide 16© ABB
ABB Mine Location Intelligence™
In cooperation with Boliden and MobilarisNovember 30, 2016
Increased safety and productivity
First level
Second level
‒ Third level
‒ Fourth level
‒ Fifth level
‒ Fifth level
Enabled by mine wide wireless communication network through WLAN (or future 5G)
3D visualization on a map Connection of people and machines
2013
John locates Tore in the
map and selects his icon
Locate People and send them a message
Boomer L2C MBR 19
FAILING
Drilling at face L25
Drilling at face L27
Drilling at face L28
Find equipment and problems
Equipment data can be integrated into maps
John starts sending Tore
a message about the
problem
Find who is closest to a problem
Find people and solve problems
21
Enter Alert text
Enter Notification text
Greate Geofence
Place markers
Create Geofence
Submit Message
Warning! Road 11 is blocked by a truck with
an engine failure. Take alternative route at
Road 700
Warning, road block ahead!
In order to redirect the traffic,
Bruce quickly creates a
geofence
Messages are generated when you enter a Geofence
Traffic Management and Geofencing
Slide 22© ABB
Rock Breaker
November 30, 2016
Remote Control Operation
Reducing unnecessary risk and travel time
Remote control desk Slave arm
Automated scheduling
November 30, 2016
Short term scheduling in closed loop
Increased utilization of machines and faces
A predictive production from the beginning of the value chain
Real-time visualization of actual status and on-line replannng
Executor
Scheduler
Monthly production plan
Personell and machine availability
Machine characteristics and distances
Work list Progress list
Progress of workWork orders
Connected to all mobile machines
Integrated Mine OperationsEnforcing operational KPIs
Enforce schedules that keep KPIs within bounds
Schedule work order execution so
as to keep the process within
bounds
Examples
Water and Power Constraints
Blend parameters
Ore origin
Trip length
Production rate
Same framework can be used to
manage of other limiting factors
such as capacity of maintenance
crews or fueling stations
without / with KPI bound enforcement
Integrated Mine OperationsEnforcing operational KPIs
Enforce schedules that keep KPIs within bounds
Schedule work order execution so
as to keep the process within
bounds
Examples
Water and Power Constraints
Blend parameters
Ore origin
Trip length
Production rate
Same framework can be used to
manage of other limiting factors
such as capacity of maintenance
crews or fueling stations
without / with KPI bound enforcement
The Internet of ThingsABB things
Smart, communicating devices by ABB
The Internet of Things (IoT) is the network of
physical objects or "things" embedded with
electronics, software, sensors, and network
connectivity, which enables these objects to
collect and exchange data [1]
The Internet of Things allows objects to be
sensed and controlled remotely across
existing network infrastructure [2]
Things Robots Motors
Switchgear Controllers
[1] "Internet of Things Global Standards Initiative“, [2] https://hbr.org/resources/pdfs/comm/verizon/18980_HBR_Verizon_IoT_Nov_14.pdf
© ABB Group
November 30, 2016 | Slide 27
Mine network architecture
Data Center(s)
Tier 3: Site Local Area NetworkWired Ethernet for Connected Devices
Tier 1(Core)
Mine operation, connectivity, and
applications
Tier 2(FAN)
Tier 2: Field Area Network (FAN)Point-to-Multipoint (PTMP), Mesh, Cellular
Tier 1: Core IP NetworkFiber, Point-to-Point (PTP) Microwave, PTMP
DHCP
AAA
Firewall
Tropos
Control
VPN
Network
Management
Network Services
and Security
Fix
ed
an
d M
ob
ile C
om
mu
nic
atio
n S
erv
ices
IDS
DNS
Wired
Wired
Wired
Video
Security
SCADA
Asset Health
Fleet Management
Tier 3(Site LAN)
Enterprise Information Services
GIS
VoIP Email Other
SCADA
Endpoints
VoIP
Phones
Video
Cameras
Trucks,
excavators,
bulldozers
Laptops,
Tablets and
Smartphones
1. One control room
2. No human presence in the production areas
3. Continuous mechanical excavation
4. Pre-concentration
5. Resource characterisation -mineralogy
6. Resource characterisation –structural control
7. Final products
8. Attractive work places
A picture of the future mineProgress
Source: RTC SMIFU report
Autonomous industrial mobile manipulation system
*In cooperation with Boliden, LKAB, NCC, Orica, RTC and Atlas CopcoNovember 30, 2016
Safer charging*
40% of all accidents happens in the charging
operation
Concept done – prototyping design to start
Move personnel from unsafe areas through increased automation
Manual work in high risk area Remote manipulation of complex task
Securing the future of miningAn Automation Platform
ABB portfolio provides visibility and
optimization across the value chain
ABB products and systems drive
fundamental change in the way a mining
enterprise works, creating increases in
Process productivity
Predictability of operations
Asset reliability
Energy efficiency
Health, safety
Protection of the environment