Mining Research Tech Center

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Visit to ABB, January 2008

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Mining Research Tech Center

  1. 1. Mining Technology Research Center (MTRC) Enrique Rubio Dpto. Ing. Minas, Universidad de Chile Rodrigo Pascual Dpto. Ing. Mecánica, Universidad de Chile et al.
  2. 2. Agenda <ul><li>Mining Industry needs </li></ul><ul><li>MTRC & PAM Lab concepts </li></ul><ul><li>ABB performance systems strategy </li></ul><ul><li>Draft a collaboration/development program </li></ul>
  3. 3. R &D Industry Needs Priorities: LT, Long term >3 years MT, Mid term 1-3 years NT, Near term 1 year Source: Copper Technology Road Map December 2006 Amira International
  4. 4. Evidence <ul><li>“… managers feel that they do not get their ideas through to the floor, while supervision and artisans feel that management are in a ivory tower - totally divorced from reality… managers want to implement new concepts, while supervision and artisans want to get on with the job... managers arrange meeting upon meeting to effect change, but without much result. On the other hand, supervision and artisans go with the flow, but keep on doing the job as ‘they know best’…” </li></ul>Fuente: J.L. Coetzee, Maintenance success using a holistic approach, Maintenex Conference, 2000
  5. 5. Strategy implementation triangle <ul><li>Typical </li></ul><ul><ul><li>to develop one or other level, i.e. </li></ul></ul><ul><ul><ul><li>developing a maintenance plan using RCM </li></ul></ul></ul><ul><ul><ul><li>Install a new ERP/CMMS </li></ul></ul></ul><ul><ul><ul><li>… </li></ul></ul></ul>Maintenance operations Maintenance information/ Operational Systems Maintenance plan Procedures Policy Gap
  6. 6. Divide & Conquer <ul><li>Slice-centered holistic approach </li></ul><ul><ul><li>Limited nr of people </li></ul></ul><ul><ul><li>Team </li></ul></ul><ul><ul><ul><li>Management & operations belong to the same project </li></ul></ul></ul><ul><ul><ul><li>Increases group cohesion </li></ul></ul></ul><ul><ul><li>Permits </li></ul></ul><ul><ul><ul><li>Use of world-class decision-aid tools </li></ul></ul></ul><ul><ul><ul><ul><li>Accelerate improvement </li></ul></ul></ul></ul>
  7. 7. MTRC Team Mathematics, U de Chile Computing Science Nelson Morales Industrial Engineering, U de Chile Operations Research Daniel Espinoza U. Adolfo Ibañez Operations Research/ logistics Marcos Goycoolea Mathematics, U. Adolfo Ibañez Operations Research Eduardo Moreno Computing Engineering, U de Chile Fast computing Maria Cecilia Rivara Mining Engineering, U de Chile Mine Design Raúl Castro Mining Engineering, U de Chile Geostatistics Julian Ortiz Mechanical Engineering, U de Chile CFD modeling Alvaro Valencia Electrical Engineering, U de Chile Robotics Javier Ruiz del Solar, Mechanical Engineering, U de Chile Risk & Reliability Rodrigo Pascual Mining Engineering, U de Chile Mine Planning Enrique Rubio
  8. 8. Vision <ul><li>Be a major player in world-leading research and development to provide new process technologies and decision aid tools to the mining industry using local challenges and knowledge </li></ul>
  9. 9. Mission <ul><li>Deliver innovative tools and expert human resources to increase productivity and safety to our mining partners and ensure a future of wealth to all members of the consortium </li></ul>Mining and basic technologies Health, Safety and Environment Operations Research Mining Business Performance Excellence & Continuous Innovation
  10. 10. Core Competences & Synergy <ul><li>Holistic mine planning </li></ul><ul><ul><li>Robust modeling </li></ul></ul><ul><ul><li>Planning horizons </li></ul></ul><ul><ul><li>Integrates the whole production chain Geo-Metallurgical planning </li></ul></ul><ul><li>Risk and Reliability modeling </li></ul><ul><ul><li>Equipment </li></ul></ul><ul><ul><li>Resources </li></ul></ul><ul><ul><li>Mining Systems </li></ul></ul><ul><ul><li>Uncertainty </li></ul></ul><ul><ul><li>Systems simulations </li></ul></ul><ul><ul><li>Contract Management </li></ul></ul><ul><li>Robotics </li></ul><ul><ul><li>View </li></ul></ul><ul><ul><li>Navigation </li></ul></ul><ul><ul><li>Communications </li></ul></ul><ul><ul><li>Control </li></ul></ul><ul><li>Numerical Modeling </li></ul><ul><ul><li>Fast computing </li></ul></ul><ul><ul><li>Geometries </li></ul></ul>
  11. 11. MTRC International Team <ul><li>Sean Desserault , Information Systems, Arizona University </li></ul><ul><li>Alexandra Newman , Operations Research, Colorado School of Mines </li></ul><ul><li>Kadri Dagdelen , Mine Planning, Colorado School of Mines </li></ul><ul><li>Roussos Dimitrakoupolos , Mine Planning, Mc Gill University </li></ul><ul><li>Matt Pierce , Rock Mechanics, Itasca </li></ul><ul><li>Italo Onederra , Blasting technologies, JKMRC </li></ul><ul><li>Emmanuel Chanda , Mining Technology, Curtin </li></ul><ul><li>Peter Knights , Reliability Modeling, Queensland University, CRC Mining </li></ul><ul><li>Andrew Jardine , Maintenance and Reliability Optimization Lab, University of Toronto </li></ul>
  12. 12. MTRC Performance excellence facilitator inside the organization MTRC Tactical Decision Makers Strategic Decision Makers Communication & cultural gaps Tech layer
  13. 13. MTRC Performance excellence facilitator across the industry Mining company Partner L1 Partner L2 Partner L2 Partner L1
  14. 14. Multidisciplinary Approach <ul><li>Example: Mine Planning- Open Pit Optimization </li></ul><ul><ul><li>Traditional </li></ul></ul>Concept Ore Body Model Formulation Algorithms and MetaHeuristics Computer Science <ul><ul><li>Proposed </li></ul></ul>Model Formulation Concept Ore Body Algorithms and metaheuristics Computer Science
  15. 15. Deliverables <ul><li>Commercialization and Technology transfer </li></ul><ul><ul><li>Development of hardware and software products </li></ul></ul><ul><ul><li>Services </li></ul></ul><ul><ul><li>Spin-offs </li></ul></ul><ul><ul><li>Small & Medium enterprises </li></ul></ul><ul><li>Research & Education </li></ul><ul><ul><li>Industry-guided </li></ul></ul><ul><ul><li>Expert human resources </li></ul></ul><ul><ul><li>Provides Dissemination seminars </li></ul></ul><ul><ul><li>Publishing in top notch journals </li></ul></ul><ul><ul><li>Presenting in seminars, conferences, workshops and training courses </li></ul></ul>
  16. 16. IP of Developments <ul><li>Belongs to the Center and researchers </li></ul><ul><li>Free use to the project sponsors </li></ul>
  17. 17. Potential sponsors <ul><li>BHPbilliton </li></ul><ul><li>Xstrata </li></ul><ul><li>Freeport </li></ul><ul><li>Antofagasta Minerals </li></ul><ul><li>Anglo American </li></ul><ul><li>ABB </li></ul><ul><li>Komatsu </li></ul><ul><li>Michelin </li></ul><ul><li>others </li></ul>
  18. 18. Board <ul><li>Membership </li></ul><ul><ul><li>1 member per sponsor company </li></ul></ul><ul><li>Functions </li></ul><ul><ul><li>Analyze strengths, weaknesses and opportunities </li></ul></ul><ul><ul><li>Set strategic policy & direction </li></ul></ul><ul><ul><li>Focus the research </li></ul></ul><ul><ul><li>Oversees commercialization & tech transfer </li></ul></ul>
  19. 19. Organization chart Chairman CEO VP-Business Development VP Research & Education VP Commercial Mine planning program Risk & Reliability program Robotics program Process modelling program
  20. 20. Centre partners <ul><li>Open, project-oriented collaboration </li></ul><ul><ul><li>Best in class center2center collaboration </li></ul></ul><ul><ul><ul><li>Other research centres </li></ul></ul></ul><ul><ul><ul><li>Universities </li></ul></ul></ul>
  21. 21. Development Plan <ul><li>Phase I (2008-2009): Acquisition and Implementation </li></ul><ul><ul><li>Building rehabilitation </li></ul></ul><ul><ul><li>Consolidate </li></ul></ul><ul><ul><ul><li>Mine Planning Lab </li></ul></ul></ul><ul><ul><ul><li>Physical Asset Management Lab </li></ul></ul></ul><ul><ul><ul><li>Robotics Lab </li></ul></ul></ul><ul><ul><ul><li>Computational Mechanics Lab </li></ul></ul></ul><ul><ul><li>Create the Distributed Mining Laboratory </li></ul></ul><ul><ul><li>Decision aid tools </li></ul></ul><ul><ul><ul><li>Integrated Reliability Modelling for Mining Systems </li></ul></ul></ul><ul><ul><ul><li>Integrated Mine planning and control systems </li></ul></ul></ul><ul><li>Phase II (2010-2011): Development/ Maturity </li></ul><ul><ul><li>Implementation full scale and performance measurements </li></ul></ul><ul><ul><li>Technology transfer </li></ul></ul><ul><li>Phase III (2012-2014): Center Sustainability </li></ul><ul><ul><li>Spin offs </li></ul></ul><ul><ul><li>IP commercialization </li></ul></ul><ul><ul><li>Technology implantation </li></ul></ul>
  22. 22. Financing <ul><li>Capital </li></ul><ul><ul><li>80% Sponsors </li></ul></ul><ul><ul><li>20% Government research funds </li></ul></ul><ul><li>Operating </li></ul><ul><ul><li>70% sponsors </li></ul></ul><ul><ul><li>30% government research funds </li></ul></ul>
  23. 23. On-going research projects at Universidad de Chile Mine planning Lab Dpto. Ing. Minas supported by BHPbilliton
  24. 24. Aplicación a DOZ ESZ PT Freeport Indonesia <ul><ul><li>Panel caving mecanizado </li></ul></ul><ul><ul><li>800 puntos de extracción a la mina completa </li></ul></ul><ul><ul><ul><li>320 ptos activos </li></ul></ul></ul><ul><ul><ul><li>50 ktpd </li></ul></ul></ul>
  25. 25. Mining plan reliability tons
  26. 26. Physical Asset Management Lab Dpto. Ing. Mecánica http://pascual.ing.uchile.cl/pamlab/
  27. 27. PAM++ http :// opam.ing.uchile.cl
  28. 28. Optimal preventive maintenance interval Acceptable CBM cost rate
  29. 29. Condition based maintenance Proportional Hazards modelling Risky zone Component age(Ton, Km, hours, op. cycles) Condition variable Jan’08: batch Jun’08: online
  30. 30. Symposiums on Physical Asset Management Encuentro en Gestión de Activos Físicos (EGAF) http:// pascual.ing.uchile.cl /egaf4
  31. 31. CORFO <ul><li>Proyectos Programa de Innovación del Cluster Minero </li></ul><ul><ul><li>Integrated Reliability Modeling for Mining Systems </li></ul></ul>

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