processing, but also exactly when it will
arrive. This allows the entire operation to
optimise its production processes to
maximise efficiency in meeting the
market’s needs. Mines using such
systems can achieve significant efficiency
improvements, sometimes as high as
5 – 10%, which are results that drop
straight to the bottom line.
Autonomy is readily accessible
around mining’s extractive processes.
More sites are beginning to use wireless
communication networks to avail
themselves of autonomous and
semi-autonomous mining applications
without human operators. These
solutions typically displace routine
transitional activities between higher
intervention processes, such as haulage,
empty LHD return, etc.
The integration of automation and
control systems with enterprise asset
management and production software
creates a broad range of opportunities to
optimise operations and meet
environmental obligations. Some
immediate opportunities include:
n
Feeding information from existing
IT infrastructure (e.g. up-to-date
customer order information, coal
movements and properties) into
the process control environment to
‘tune’ plant to product characteristics
and quantities to real-time market
conditions.
n
Combining production demand,
employee availability and condition
monitoring data to prioritise
production and maintenance based
on impact to schedule and contract
fulfilment.
n
Monitoring environmental impact.
How can automation help?
Automation can offer mining operations
a detailed overview of critical processes.
This equips mines to better manage an
increasingly complex environment
governed by changing regulations and
volatile pricing.
For example, various coal mines in
Europe employ Intelligent Mining
Solutions (IMS) fromABB to increase
operational visibility and improve
productivity. In particular, the geological
modelling and design package,
MineScape, is used for accurate reserve
calculation and input into the blending
process – ensuring more efficient and
accurate blending to meet customer
specifications. MineScape also supports
short- and long-term planning and
scheduling, providing visibility not only
on future production, but also for
monitoring environmental concerns,
such as ground water tables.
IMS solutions are part of some highly
sophisticated and automated coal
operations in Europe where, through the
use of GPS and remote steering systems
at one operation, mining cut designs
fromMineScape are transferred
wirelessly from the office to the machine
for the design to be applied in the field.
However, within many mining
organisations, the use of disparate
systems has often led to inconsistent
processes and conflicting information
contributing to time-wasting disputes,
errors and high overheads. Data from all
supply chain points through to details of
contracts, invoices and payments, tend to
be owned by individuals within
organisation silos.
To meet the demands of complex
contracts and manage sophisticated
logistics profitably, it is increasingly
crucial to consolidate and better manage
the spectrum of operational data, as well
as make it easily visible to all
stakeholders. Additionally, with
companies subject to greater internal and
external scrutiny, being able to efficiently
track and verify commercial data trails is
critical.
Mining innovation is being driven by
the convergence of OT and IT. More data
is flowing from connected equipment
and devices reporting to operational
systems in real-time. Mining IT elements
now produce more accurate and reliable
information that can be used to
significantly improve decision-making
across production outcomes. The
combination of process automation and
control, business intelligence, analytics
and financial applications, as well as
wireless communication networks,
allows operations to integrate, analyse
and refine this data – resulting in
improved performance.
Smarter mining solutions are thus not
only in use at mine sites, but also at
marketing desks to coordinate the global
sale and delivery. With a fully integrated
view of the coal production process from
mine to rail to port, for example,
marketers can achieve greater efficiency
and secure delivery to the global market.
Software solutions, such as
MineMarket, can maximise commercial
outcomes by optimising logistics,
charting sales impact, while tracking and
identifying operational bottlenecks. Such
systems minimise data collection delays,
ensuring the same information is visible
organisation-wide, as well as facilitate
analysis, adjustment and reconciliation.
These solutions allow each operational
area of the mine, and headquarters staff,
to align performance with real-time
customer needs, while allowing the
information from various systems to be
aggregated into a single source of the
truth for the purposes of operational and
planning decision-making.
By bringing together islands of
automation and ensuring everyone has
access to all information in real-time
through the same viewing platform, it is
easier for all functions and interface
systems to agree the way forward as
there is a common perspective resulting
in efficiency benefits throughout.
To illustrate, consider stacking
operations. Process control platforms,
such as ABB’s System 800xA, can
collect, aggregate and send the stacking
information as a series of transactions
(e.g., tonnes, position and grade) to
MineMarket via integration
middleware. This transactional
information can then be stored using an
advanced 3D stockpile modelling
system, allowing users to visualise the
stockpile quantity and quality in any
given section. During plant feed
operations, the System 800xA queries
MineMarket for the material qualities of
the next reclaim operation and can
adjust the processing plant
characteristics to optimise performance
and maximise profits from the yield.
Significant productivity improvements
can also be achieved through the
increased use of automated equipment.
Allowing underground equipment to
operate in an unmanned state during
adjacent underground blasting or
development work, or through shift
changes, provides additional production
working hours. Throughput and
production volumes are less operator
50
|
World Coal
|
December 2015
