Trends in Control and Power Technologies and Its Impact for Mineral Recovery Rates
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Presented at the 2013 Society of Mining, Metallurgy and Exploration Annual Meeting (SME 2013). Mineral processing presents a major process challenge as it involves complexities in extraction and transformation into a final product, but also requires huge material movement, scheduling, and tracking. Learn how trends in information systems, reporting systems, energy management and efficiency, communications, process control, plant integration and other control technologies are aligned to address these current industry challenges.
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Trends in Control and Power Technologies and Its Impact for Mineral Recovery Rates
- 1. TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES Rolan Marrill, National Account Manager Mining, Minerals and Metals Schneider Electric SME Annual Meeting and Exhibition 2013
- 2. Trends and its impacts Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 3. Mining Industry is facing unprecedented challenges: Asset Safety People Lack of Skilled Safety People More Ore, Control Systems Process by Growing Larger Plants & More Complex Equipment Mining Business More Energy Decline Of Delivered Mineral by Larger Grade and / Complex Reserves Systems Cost Escalation for Regulations New Developments Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 4. People Safety Evolution Control Room Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 5. Lock Out and Tag Out (LOTO) Failure to Lock Out and Tag Out (LOTO) equipment power sources continues to result in mine fatalities. Figure 1. View down an else in an Electrical Figure 2. Arc Fault Event, created in equipment room. (Open Source on Internet) Power Research Lab Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 6. ● Engineer the system for safety and reliability ● Studies completed to identify the hazards. (Reliability = Improved safety) ● Training is critical and maintaining a staff of qualified people is a must. . Skilled Skilled People People Personals Personals ++ Safety Safety Training Training Reliability Reliability Asset Asset Safety Safety Figure 3. Installation of new Circuit Breaker in Existing 480 Volt Distribution Equipment.) Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 7. ● Upgrade systems (or Retro Fit) latest and best protection systems for your application. Skilled Skilled People People Personals Personals ++ Safety Safety Training Training Reliability Reliability Asset Asset Safety Safety Figure 4. Switchgear Virtual Main Arc Flash Mitigating System (SVMS) Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 8. ● Engineered solutions and products can be used to reduce incident energies. No one solution nor product is a “fix-all” in these complex electrical systems. What works in one system will not provide any additional benefit or protection in another. Skilled Skilled People People Personals Personals ++ Safety Safety Training Training Reliability Reliability Asset Asset Safety Safety Figure 6. Picture of Low Voltage Motor Control Center Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 9. Energy as the new process variable Control Room Evolution Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 10. Energy and Mining ● Understanding benefits of metering at critical points and control of energy uses from a top-down, high- level understanding will aid in obtaining the most efficiency out of the energy consumed. ● Energy Efficiency concerns have driven the application of sophisticated power correction and harmonic correction systems in the mine electrical systems. ● Input from knowledgeable electrical engineers and consultants will aid in making the best decisions for overall Energy Efficiency. Figure 7. View of operator using Power Management Software Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 11. Control Room Evolution Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 12. Control Room Evolution Figure 9. Modern Control Room Figure 8. Control Room with Annunciation panels ● Industries no longer see annunciator panels. Now the standard is a bank of high definition monitors spread across the control console. ● Demand for more realistic and detailed graphics ● Use of video cameras and other technology allows operators visual real-time Figure 10. iPad(R) with control application running views in the facilities. Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 13. Control Room Evolution-Get Ready for change Figure 10. iPad(R) with control application running Figure 11. Head gear with graphic display Open Source Internet ● More and more business management professionals are moving their daily •These modernized control centers business functions to devices such as and control rooms enable an an iPad or a tablet. additional benefit that simulators can and will be used to train the new operators in a very realistic setting. Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 14. The Information Revolution Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 15. Communications and Data are now everywhere. ● Industries have more data from more sources every day and the need for systems to help manage all this information has never been greater. ● There is a need to get more out of these processing plants than ever before. ● The mining boardroom considers the process and production improvements to be gained as very desirable, since the risk of production loss or reduced production is very unacceptable today. Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 16. How to manage and align all this data. ● Advanced software systems sometimes called mine execution systems (MES) are helping management and operational teams reduced downtime, improve overall throughputs, track inventory, and manage energy. ● Occasionally, in mining operations the dilemma is the excess of information. ● True pit-to-port or mine-to-finished product delivery solutions enable management to see production and corresponding results in profit and loss. ● These systems enable all key operation people to see the impacts of each outage, slow down, or improvement in production. ● MES systems also help identify costs by To Quote Lee Freeman: area or action to give operations the tools to better manage and maximize “I now know more, then I understand…” profitability. Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 17. Network Security and Growing Role of IT Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
- 18. Network Security and Growing Role of IT ● Devices need to be equipped with some form of protection ● Control systems will have to be able to identify and cross- certify the authenticity of the commands from mobile devices Figure 12. Picture of a Data Pod ● IT departments in mining (Small Modular Data Center) sector are growing ● Much of the data that the industry now manages is digitalized and networked ● Process Control Experts becoming IT experts Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 19. Conclusions ● Safety will remain a key issue and driver of research and development of new electrical equipment and solutions. ● Training in all aspects will continue to evolve and adapt new technologies ● More energy will be used in processing low- grade ores and in the future the demand for technology will continue to be developed to meet the needs of the mining community. Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 20. Conclusions ● More source points of information will be required and collected. ● Demand for easy-to-read dashboards and reports will continue to rise. ● Rise of mobile applications for control and monitoring ● More integration of process and production into business tools Figure 13. Control Room Dashboard Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 21. Conclusions ● Improvements will include but are not limited to: ● Expert systems ● ERP ● MES ● LIMS ● PIMS ● Quality control ● Asset management ● Dispatch systems ● Mining planning Figure 6. View of operator using Power ● Mine scheduling Management Software ● Energy management ● These systems, when well integrated and utilized can show the efficiencies to be gained in the process, operations, and energy consumption of mining plants Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Schneider Electric Presentation Title – SME 2013 Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
- 22. Thank You! Schneider Electric – - Industry IN CONTROL AND Manage Your Legacy Automation ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013 Schneider Electric TRENDS Business – How to POWER TECHNOLOGIES AND Equipment – 2012
Editor's Notes
- These accidents could have been prevented by electrically disconnecting power and assuring it is OFF, having each miner on the job lock the power source in the safe position, and attach his or her personal safety lock and tag to prevent reconnection and re-energization
- variable frequency drives, capacitor banks Some of these systems will have a direct payback, others will have indirect or cost avoidance paybacks. Many mining and industrial companies are already using many combinations of these systems to improve their overall electric efficiencies. The Real Savings; however, will only come from active management systems.
- Over time graphic displays have changed to mimic the graphics in video games in their detail and realism. Soon the industry could see 3-D display with all of the applications rotatable and viewable from just about any angle that could be imagined.
- These devices provide the ability to see their entire business matrix and have the functionality of being able to communicate at their fingertips, changes and adjustments to both the business matrix and key performance indicators (KPI). These devices enable quick response for required actions by workers not able to remain at a desk . This will reduce errors and lost production when new operators take over. Technologies such at Second City have been adapted for use in training. These virtual platforms, once developed, can allow training to occur anywhere on any subject and can even be instructor lead.
- With declining grades and larger plants there is a growing need to have complete control of the process, the need to understand the business KPI’s, and how both affect over all profits and losses.
- Many of today’s control rooms have all of the business KPI layered in right above the process control and operational databases. A myriad of dissimilar and eventually proprietary systems like Process control, Expert systems, ERP, MES, LIMS, PIMS, Quality control, Asset Management, Dispatch systems, Mining planning, Mine scheduling, and Energy management are delivering tons of data that can be useless if not treated, filtered and integrated.
- Moving forward with these technologies, new issues and concerns will arise. For example, network security and reliability will become a key factor in control and management of these complex processes. Not necessarily for the device, but for the access the device offers into operations and business systems. One only has to look at the growth of the IT departments in the mining sector to see how critical their involvement will be in the future of plant operations and control. and this has led to the modern process control expert to becoming an IT expert as well. In many cases, the industry now employs IT professionals to help at all levels of the corporate
- As these products and solutions are developed, engineering will review and apply solutions and products that meet the requirements and provide the benefits demanded. as tools to assist and complete the training of the next generations of miners both from a regulatory and profitability obligation.
- more data from all sources will be collected on the various metrics in mine operations. The need to have ways to consolidate this data and metrics into readily understandable dashboards and reports will continue to rise. More development of mobile applications will continue due to need for process plants from both operations and business aspects. Management will need and demand integration of process and production. These tools will provide real time understanding of any issues that influence production and profits. By moving forward with improvements, integration into the Enterprise Business Management Software will cut cost, improve over all performance, and reduce errors in reporting.
- and give us the control and business management tools to receive all the benefit from the energy purchased.