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PES: An Innovative Approach to Process Control Systems (and Energy Management) for Mining

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Process control technologies have evolved over the years to meet the ever-changing demands of mining operations caused by factors ranging from grade decline to strict regulations as well as the changing workforce.
The next step in this evolution needs to address this new reality where engineering efficiency and process optimization are a must, while also adding further efficiencies and visibility into energy usage and spend.
PlantStruxure PES (Process Expert System) is the next generation Process Automation Systems developed to address the ever increasing demands and constrains of today’s mining and mineral processing operations.
This presentation explores…
§ The integration control and power - making energy as an active part of the process
§ How PlantStruxure PES helps to streamline the engineering development for new mines or expansions
§ A single and simple environment - making operation and maintenance easier
§ A preview of the software that’s the foundation of the system

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PES: An Innovative Approach to Process Control Systems (and Energy Management) for Mining

  1. 1. PES: An Innovative Approach toProcess Control Systems (andEnergy Management) for MiningMining Metals and Minerals competency center
  2. 2. ● Workforce crisis● Skills shortage● Minerals scarcity● Extreme mining● Grade declineKey Trends in MiningIn mining, energy can be up to40% of the total cost of its supplies
  3. 3. By 2013, the demand formining engineers isexpected to exceed supply byTalent Strategy Advisors
  4. 4. Implications of Trends and Needs●Less funds available●Reduced workforce (less resources todevelop in-house solutions or no coreactivities)●Need to produce more with less●Minimize design time●Optimize project cost●Operating cost reduction●Maintenance cost reduction
  5. 5. Automation and ProcessControl
  6. 6. HybridProcessMiningMetalsCementF&BThe Conventional SolutionsContinuousProcessOilChemicalsPowerManufacturingAutomotiveMachineryComplex ProcessLoopsHi-AvailabilityProcess LanguageDiscreetInterlockingElectrician LanguageDistributedControl (DCS)ProgrammableController (PLC)
  7. 7. Industry Answer?DistributedControl (DCS) ?ProgrammableController (PLC) ?Hybrid Control System(HCS)?Process AutomationController(PAC)?CollaborativeAutomation Systems?
  8. 8. ●Simple to:●Design●Operate●Maintain● Troubleshooting●Remote access●Intuitive●Simple to modify, improve and expand●Reuse●Online changes●Future proof technologies●Easy interaction with other systems(MES/Energy/Instruments)Users need a system...
  9. 9. ...that represents a real applicationCrushingCrushingMillMillFlotationFlotationHomogenizationYard / StackingHomogenizationYard / StackingWater TreatmentWater TreatmentProducts YardProducts YardSchneider MineSchneider MineReclaimingReclaiming
  10. 10. CrushingCrushingMillMillFlotationFlotationHomogenizationYard / StackingHomogenizationYard / StackingWater TreatmentWater TreatmentReclaimingReclaimingProducts YardProducts YardSchneider MineSchneider Mine
  11. 11. The System Translates Each MiningOperationP&ID DiagramApplication● Model the application as it is in the real world and improve the reusabilityProcess
  12. 12. One Single Environment/PackageSupervisionSystemConfigurationProcessDesignLogicAlarms
  13. 13. Concurrent Engineering● Facilitate communication about designenhancements and process adjustments● Delegate sections of PROCESS to variousstakeholders, not sections of CODE● Tear down barriers between Maintenanceand Engineering departments to get up andrunning fast● Several users can work on the samelibraries and applications simultaneouslyfrom different work stations● Check-in and check-out features aremanaged by the system and the user isalways informed about the status of theapplications
  14. 14. Single Distributed Configuration
  15. 15. Object Oriented
  16. 16.  An integrated object offersconsistent functionality throughoutthe system The model is open and extensibleso engineers can build their ownobjects if needed The system takes care of theapplication lifecycle, managing thechanges needed throughout theplant lifeEnsures consistency across your system and drives operational efficiencyObject Oriented
  17. 17. ●Dedicated Libraries●Control Devices● Drives, motor starters, powermeters, energy consumption, etc.●Process control● Signal conditioning, process loop,sequence logic, motor control,etc.● Users can modify and/or create theirown libraries● With diagnostic and maintenanceinformation for operators andmaintenance staff●User guides, maintenanceprocedures, etc.Dedicated Process Libraries
  18. 18. Built-in Energy Efficiency● Real-time power consumption● Dedicated libraries and applicationtemplates to help reduce energy waste● Built-in “idle state” services forequipment that can be triggered basedon stoppages or other process statuses● Combined production and energy datato generate predictive maintenancealerts for equipment to reduce energyuse and downtime
  19. 19. A Dynamic Demo of the Softwarethat Powers the System
  20. 20. TrendsTrends EnergyManagementEnergyManagementIntelligentMotorControlIntelligentMotorControlAdvancedProcessControlAdvancedProcessControl
  21. 21. Make the most of yourenergy

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