Giuseppe Di Marco, ABB: Automation technologies - key for integrated mine to port solutions


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Giuseppe Di Marco, Head Global Mining Business, ABB delivered this presentation at the 2013 Americas Iron Ore conference. Americas Iron Ore is one of the most respected annual gatherings for North and South American iron ore markets. The agenda features iron ore industry and market developments; new project developments and expansions in North and South America; overview of steel demand; iron ore spot market price; infrastructure and transport challenges and investment opportunities.
After five successful editions, the Americas Iron Ore Conference consolidates as the largest meeting place for executives and professionals of the steel and iron ore industry in the region. For more information, please visit the conference website:

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Giuseppe Di Marco, ABB: Automation technologies - key for integrated mine to port solutions

  1. 1. Guiseppe di Marco, President ABB in Mining, 6th Americas Iron Ore Conference, Rio de Janeiro, 12 Nov 2013 Automation technologies Key to integrated mine to port operations
  2. 2. A global leader in power and automation technologies Leading market positions in main businesses § § $39 billion in revenue (2012) § Formed in 1988 merger of Swiss and Swedish engineering companies § Predecessors founded in 1883 and 1891 § © ABB Group November 11, 2013 | Slide 2 145,000 employees in about 100 countries Publicly owned company with head office in Switzerland
  3. 3. How ABB is organized Five global divisions Power Products Power Systems Discrete Automation and Motion Low Voltage Products Process Automation $10.7 billion 36,000 employees $7.9 billion 20,000 employees $9.4 billion 29,000 employees $6.6 billion 31,000 employees $8.2 billion 27,000 employees (2012 revenues) § ABB’s portfolio covers: § Electricals, automation, controls and instrumentation for power generation and industrial processes § § Distribution solutions § © ABB Group November 11, 2013 | Slide 3 Power transmission Low-voltage products § Motors and drives § Intelligent building systems § Robots and robot systems § Services to improve customers productivity and reliability
  4. 4. Power and automation are all around us You will find ABB technology… orbiting the earth and working beneath it, crossing oceans and on the sea bed, in the fields that grow our crops and packing the food we eat, on the trains we ride and in the facilities that process our water, in the plants that generate our power and in our homes, offices and factories © ABB Group November 11, 2013 | Slide 4
  5. 5. Ground-breaking and nation-building projects Pushing the boundaries of technology Mine hoist for largest potash mine First commercial wave power plant Longest underwater power link First platform connected to mainland grid Most remote offshore wind farm linked to grid Europe’s largest thermal solar power plant Largest battery Longest and highest capacity power link Largest SVC installation Longest conveyor belt Automation of largest alumina plant Longest underground power link Largest gearless mill drive (for crushing ore) First 600 kV power link © ABB Group November 11, 2013 | Slide 5 Largest SCADA network Largest reverseosmosis desalination plant Power and automation of largest chemical cellulose plant Substation in world’s tallest building
  6. 6. Innovation is key to ABB’s competitive advantage Leadership built on consistent R&D investment § § § More than $1.4 billion invested annually in R&D 8,000 scientists and engineers Collaboration with 70 universities § © ABB Group November 11, 2013 | Slide 6 MIT (US), Tsinghua (China), KTH Royal Institute of Technology (Sweden), Indian Institute of Technology (New Delhi), ETH (Switzerland), Karlsruhe (Germany), AGH University of Science and Technology (Poland)
  7. 7. Content § § ABB’s system approach - iron ore value chain § ABB Ventyx solution suite § Integration of information und operation technology § © ABB Group November 11, 2013 | Ver. 1.1 Slide 7 Introduction Conclusions
  8. 8. Introduction Iron ore value chain
  9. 9. ABB in mining Key facts § § Combines global and local ABB competencies and resources to ensure optimum service § About 3000 employees in 35 operating countries § > 60 complete plant electrification systems § > 120 gearless mill drive systems § > 300 belt conveyor solutions § > 600 mine hoist systems § © ABB Group November 11, 2013 | Slide 9 Offers comprehensive market-leading packages of ABB competencies, products and services for the complete production chain in mining and mineral processing industries > Automation for all the above
  10. 10. The top challenges for global mining companies Source: 2012 Mining Executive Insights Ventyx survey Reserves in remote areas with a lack of infrastructure and political and environmental risks request rising CAPEX Iron ore market has become more volatile and short-term oriented Labour is more costly, energy costs are going up and volatile prices put pressure on margins and cash flow The bottom line: How to continue to deliver high returns to shareholders © ABB Group November 11, 2013 | Slide 10
  11. 11. Iron ore value chain From mine to market Exploration, assessment Stockyard load out Planning, scheduling Rail transportation Drill and blast Train unloading Load and haul Processing Stockyard blending Ship loading Achieve overall optimization of quantity and quality of supplied material, eliminate suboptimized islands © ABB Group November 11, 2013 | Slide 11
  12. 12. Integrated Automation § § Should supply a consequential sequential effect analysis on the entire process when one of the items within that process defaults or gets changed § should permit immediate remedial actions to maintain the required level of productivity and plant availability at all times. § Should promote collaboration along the whole Production Process § © ABB Group November 11, 2013 | Slide 12 Should provide all data required to manage the value chain at all times along the whole production process Should permit Remote Operations favouring the unmanning (less people underground) and un-trucking (truckless) of Mines
  13. 13. ABB system approach Iron ore value chain
  14. 14. Iron ore processing portfolio (1 of 2) ABB integrates solutions … Mining Beneficiation Transportation Shovels Crushing Belt conveyor systems Inpit crushing SAG mill Slurry pipeline Belt conveyors Ball mill Railway systems Stockyard systems Screening Fleet management Flotation / Separation Stockyard mgt system Stockyard systems Mine hoists Electrification and automation with Special mining drive solutions Gearless conveyor drives Double drum & friction hoists Incl. brake systems & shafts Electric UGM trucks, ventilation on demand Power generation, conversion& distribution Gearless mill drives (GMD) Ring-geared mill drives (RMD) High pressure grinding rolls (HPGR) applications – variable-speed drive Plant infrastructure & optimization Rolling stock & rail networks Conveyor systems Loading and unloading facilities Stockyard management Collaborative production management Integrated electrification, automation, control, instrumentation, drives & CPM solutions Services © ABB Group November 11, 2013 | Slide 14
  15. 15. Iron ore processing portfolio (2 of 2) … to optimize productivity and efficiency Pelletizing Terminal DRI Melt shop Dewatering, filtering Train loading/unloading Gas supply Electric arc furnace Grinding Blending Direct reduction Blast furnace Balling, induration Ship loader / unloader Hot briquetting Electrification / automation Variable speed drives Power distribution Process control & optimization Instrumentation Collaborative production management Conveyor systems Unmanned operation of S/R Stockpile management Quality management Logistics and sales management Compressor drives Power distribution Ex protection equipment Process, safety control Instrumentation, valves Collaborative production management Furnace transformers Static Var compensation Power distribution HV/MV substations Rectiformers DC/AC furnace electrification Metalurgical steerers & breaks IntegratedIntegrated Electrification, Automation, Instrumentation & Drive Solutions & CPM solutions electrification, automation, control, instrumentation, drives Services © ABB Group November 11, 2013 | Slide 15
  16. 16. ABB road map - strategy Hollistic view to information Enabling collaboration and integrated decision making Design Production Assets Production plan Work Material People Real time report Asset availability Finance Status on-line Demand Control, monitor in real time Optimize based on plan and demand One operation ”Set points” Real time data Control system Control system Control system Control system Control system Control system Control system Control system Control system Drill rigs Shovel Truck/fleet management Crusher Benefication Pelletizing Stockyard Terminal Electrical power distribution © ABB Group November 11, 2013 | Slide 16
  17. 17. ABB portfolio Extended automation System 800xA © ABB Group November 11, 2013 | Slide 17
  18. 18. Extended Automation System 800xA Integration: One common automation platform Benefits include § Efficient engineering § Organization of information § Shared data § Data that comes from various sources can be accessed by multiple applications without separate interfaces!
  19. 19. Promoting collaboration Integration of process and power automation Process and power workplaces Control room Same operations interface and engineering for shared information and knowledge Plant-wide sequence of events for better root cause analysis Control system Plant network Process control server Standardized procedures, Standardized procedures, settings, control logic and settings, control logic and libraries libraries Centralized historian and data archiving Control Common system therefore reduced spare parts, training etc… Controller Controller Profibus/Profinet IEC 61850 Electrical integration LV switchgear, based on open standards drives, motor such starters as IEC 61850, Protection & control IEDs Profinet/Profibus… Instruments Process Process instrumentation Process electrification Common, integrated Centralized asset management Historian and strategyArchiving Data Substation automation
  20. 20. Integration of automation and electrical devices One system approach Extended operator workplace Operation, engineering Process & Ventyx maintenance optimization Ventyx production management Headquarter ERP and business systems ECS, ISA-95, OPC… Firewall router System servers AC800 M process controller Corporate network Mobile / remote operation engineering and maintenance High integrity control safety shutdown fire and gas Sub system controller AC800 M Drive systems for grinding Main process and power control © ABB Group November 11, 2013 | Slide 20 Automation system network Wireless communication Automatic stockpile loading, unloading transport 800xA based integrated sub systems
  21. 21. ABB Ventyx solution suite Mining © ABB Group November 11, 2013 | Slide 21
  22. 22. ABB - Ventyx solution suite Ellipse - Asset and work management Ventyx Production Accounting – Mass balance & reporting MineMarket – Product logistics and sales MineScape – Geological modeling, mine planning, mine operations CCLAS – Production quality and laboratory management 800xA - Process Control Geological, mine plan, mine operations © ABB Group November 11, 2013 | Slide 22 Ore & metal processing Product handling & transport Shipping & sales
  23. 23. MineScape: geologic modeling Creating a 3D map of the ore body © ABB Group November 11, 2013 | Slide 23
  24. 24. MineScape: mine plan and schedule Decisions support for optimal mine operations © ABB Group November 11, 2013 | Slide 24
  25. 25. Ventyx Production Accounting Consolidate information: one single auditable version of the truth Financial management system (e.g. ERP) Mass, KPIs, metal content, inventories Metal accounting business process Acquire Validate Authorize Calculate Report Publish Analyse Wet tons, volume, assay, mass, moisture, density, transaction, shift, day, week, month © ABB Group November 11, 2013 | Slide 25 Audit
  26. 26. MineMarket: inventory management Know where and which material you have in the value chain © ABB Group November 11, 2013 | Slide 26
  27. 27. MineMarket: ship loading and unloading Ensure optimal ship loading according to market demand and enterprise capacity © ABB Group November 11, 2013 | Slide 27
  28. 28. MineMarket: sales and marketing Automatically generate correct invoices and certificates © ABB Group November 11, 2013 | Slide 28
  29. 29. MineMarket Visualize logistics through the value chain © ABB Group November 11, 2013 | Slide 29
  30. 30. ABB and Ventyx joint value IT/OT case studies © ABB Group November 11, 2013 | Slide 30
  31. 31. Grinding optimization Variable-speed drives and advanced process control Value proposition § Variable-speed mill drives enable real time mill speed optimization for higher grinding efficiency Technology § Combine variable-speed drive and advanced process control to increase grinding process performance § Mill fill “indicators” as key measurement Benefits § More production § Higher energy efficiency § Longer liner lifetime © ABB Group November 11, 2013 | Slide 31
  32. 32. Use case Advanced Process Control in grinding Inventory management & APC for optimal ore grinding © ABB Group November 11, 2013 | Slide 32
  33. 33. Concentrator operations Leveraging IT/OT convergence (OT) Advanced process control (APC) manages blending, grinding, flotation in real-time (IT) Geological model and real-time material tracking provides short term feed characteristic schedule to APC (OT) Advanced process control (APC) uses the information to increase performance and quality in realtime The old way § § § § Production, equipment and other control systems not integrated No information on relative product pricing No information on feed material Plant set points static Value proposition (OT) Online analyzers and blending algorithms reconcile actual feed with quality specifications for better predictability © ABB Group November 11, 2013 | Slide 33 (IT) Sales system periodically provides relative pricing updates to APC (OT) APC refines control set points to maximize recovery and energy efficiency for current feed material and product pricing Increase plant recovery and optimize product mix based on current pricing and ore feed properties through leveraging APC across processes and business systems
  34. 34. Example: Stockyard management Manless operation, blending and material tracking Value proposition § Fully automatic stacking/reclaiming § Material tracking and blending with 3D online visualization § Task scheduling Technology § Laser scanner and GPS based control (BulkExpertTM) § Microsoft technology for visualisation Benefits § Less personnel § Higher efficiency and throughput § Lower wear and maintenance efforts © ABB Group November 11, 2013 | Slide 34
  35. 35. Stockyard operations Leveraging IT/OT convergence (IT) 3D modelling with real time reconcilations by 3D –laserscanners (OT/IT) ore blending to requested quality based on quality management and pile visualisation (OT) Task scheduling to synchronize train and ship logistics The old way § § § § Production, equipment and other control systems not integrated No exact information on material distribution by quality and location No synchronization between train and ship logistics stockyard set points static Value proposition (OT) Online analyzer integration and material tracking providing real-time data © ABB Group November 11, 2013 | Slide 35 (IT) Sales system periodically provides contracting updates to stockyard Management (OT) Stockyard management refines control set points for blending algorithm and routing path selection Increase stockyard throughput with optimized product mix based on contract demands and mine output
  36. 36. Integration of Ventyx Ellipse in 800xA workplace Maintenance information available in real time © ABB Group November 11, 2013 | Slide 36
  37. 37. Integration of Ventyx Ellipse in 800xA workplace Maintenance information available in real time © ABB Group November 11, 2013 | Slide 37
  38. 38. Conclusions © ABB Group November 11, 2013 | Slide 38
  39. 39. ABB’s integrated mine operating model IT and OT enable collaboration and optimization Collaborate Monitor & control © ABB Group November 11, 2013 | Slide 39
  40. 40. ABB Technologies Mine enterprise management from mine to port © ABB Group November 11, 2013 | Slide 40