African Minerals Ltd

IRON ORE PROCESSING IRON ORE PROCESSING STAGE 1B STAGE 1B

ATATAFRICAN MINERALS LTD.,AFRICAN MINERALS LTD.,

TONKOLILITONKOLILI

Overview of PresentationOverview of PresentationIndustry OverviewIndustry OverviewProcess OverviewProcess Overview

Iron ore Process Iron ore Process Project OverviewProject Overview

System ArchitectureSystem Architecture Software’s usedSoftware’s used PLC Code Programming StructurePLC Code Programming Structure SCADASCADA

Industry OverviewIndustry Overview

African Minerals has been active in Sierra African Minerals has been active in Sierra Leone since 1996.Leone since 1996.Phase I production capacity increased from Phase I production capacity increased from 15Mtpa to 20Mtpa and low cash costs expected 15Mtpa to 20Mtpa and low cash costs expected at under $30/t..at under $30/t..

Industry OverviewIndustry Overview

Established in 1991 .Established in 1991 .Mining industry experts - for the delivery of turnkey Mining industry experts - for the delivery of turnkey Mining process projects.Mining process projects.AML Plant total designed by Ausenco.AML Plant total designed by Ausenco.

Industry OverviewIndustry OverviewLV Systems LV Systems

InstrumentationInstrumentation

Control SystemsControl Systems

Plant Management SystemsPlant Management Systems

Support & MaintenanceSupport & Maintenance

Plant InstallationsPlant Installations

What is Iron Ore??What is Iron Ore??Iron ore is any rock or mineral from which Iron ore is any rock or mineral from which

iron can economically be extracted form of iron can economically be extracted form of iron oxides such as magnetite.iron oxides such as magnetite.

Ore contain between 25% to 60% iron.Ore contain between 25% to 60% iron.

Iron Ore ProcessIron Ore Process

overview

Iron Ore ProcessIron Ore ProcessROM bin continuous level transmitter Lo Level to activate Green light for front end loaders to fill the ROM bin.

Hi Level to activate Red light for front end loaders to stop filling the ROM binApron FeederApron FeederSpeed Controlled by WIC in Automatic mode, or Operator set point in ManualRoller ScreenRoller ScreenRoller Screen Contain 8 motors. If any motor stopped due to Motor jam. Then all 8 motors stop and wait 5 sec Restart the Roller in Reverse. Run the Roller in Reverse for 10 seconds Stop the Roller for 5 seconds. Start the Roller Forward. All the operation in Auto mode


Over Land Conveyer Over Land Conveyer after primary crushed iron ore Transfer to Scrubber by using over land conveyer.(2.5 Km Power Regeneration Drive)

The Over Land Conveyer generated 1 Mw Power.

DOUBLE ROLLS CRUSHERDOUBLE ROLLS CRUSHERThe drive cannot be started/stopped individually from the PCS. The Crusher Drives Will Start and Stop as One Drive

Iron Ore ProcessIron Ore ProcessScrubber Feed Diverter ChuteScrubber Feed Diverter Chute

Move to Dump position when either Scrubber, CV003, Screen1 or Process water pumps any one stop Diverter Chute move to Dump position

Iron Ore ProcessIron Ore ProcessCrushed ore delivered from the overland conveyor discharges into the scrubber where process water is added. The ore is scrubbed and clay minerals are washed from the ore surface before discharging from the scrubber via the discharge trammel, which has a screen aperture size of 32mm. The trammel oversize material discharges to the cone crushing circuit while the undersize material gravitates to the coarse screen. ScrubberScrubber


Tailing ThickenerTailing Thickener

The coarse screen (8mm aperture) oversize discharges onto the lump product conveyor, and undersize slurry gravitates to the fines dewatering cyclones feed hopper. Slurry from the fines dewatering cyclones hopper is pumped in two parallel closed circuits of feed pumps, dewatering cyclones and dewatering screens. Overflow from the cyclones discharges to the tailings thickener.

Thickener under flowThickener under flowThere are three thickener underflow pumps, each with dedicated discharge lines to the tailings hopper. To enable recycling of slurry back to the thickener, when required, two of the pumps are provided with recycle lines to the thickener feed tank.

All three of the pumps can be variable speed controlled and have dedicated Flow & Pressure Cascade control loops. The number of pumps required to run at any one time will depend upon the ore type being fed into the process. More pumps will be required to run if the ore contains a large amount of fine material.

Iron Ore ProcessIron Ore ProcessFrom Scrubber over Size ore going to Cone Crusher and Normal Size go to Dry Screen. Cone Crusher Crushed the ore and send to Dry Screen. After Screen Lump Ore transfer to Lump Product House. Cone Crusher Cone Crusher

Controlled by vendor supplied LCP but remotely started and stopped from the PCS. The amount of cone crushers to run will be determined and selected by the operator based on the type and amount of ore being fed to the process. The cone crusher is selected to Auto on the LCP if it is required to start and stop remotely.


From Product House to Stock Dump yard going through Stacker’s

(Lump’s & Fine’s).Stacker’sStacker’s

The finished Iron Ore transferred to Port by Train.

And Fine direct Separated from Scrubber Outlet its transfer to fine Product house.

IRON ORE PROCESSING IRON ORE PROCESSING STAGE 1B STAGE 1B

ATATAFRICAN MINERALS LTD.,AFRICAN MINERALS LTD.,

TONKOLILITONKOLILI

The Aim of This Project was :-The Aim of This Project was :-

1.1. To reduce the Time and Logistic To reduce the Time and Logistic This Process plant to increase in production This Process plant to increase in production 1800Tph. 1800Tph.Overall increase in capacity 15Mtpa to Overall increase in capacity 15Mtpa to 20Mtpa .20Mtpa .

System Architecture

This project utilizes Schneider-Quantum-140 CPU This project utilizes Schneider-Quantum-140 CPU 652 60 02.40, No- 4 PLC’S652 60 02.40, No- 4 PLC’S

ModiconM340-BMX P34 2020 02.10, No-4 PLC’sModiconM340-BMX P34 2020 02.10, No-4 PLC’sSoftware-Unity Pro XL V 6.0,Vijeo Citect 7.2, Software-Unity Pro XL V 6.0,Vijeo Citect 7.2, Pro Soft V 2.3.2.2, Power Suite v 2.6.1. Pro Soft V 2.3.2.2, Power Suite v 2.6.1.

System ArchitectureSystem Architecture

FOFO

Primary Crusher Primary Crusher AreaArea

Dry Screen AreaDry Screen Area

Raw Water AreaRaw Water Area

Jozi Power AreaJozi Power Area

Server RoomServer Room

EHEH

Op station 2 Op station 2 Op station 1 Op station 1 Engg station Engg station

Scrubber AreaScrubber Area

Scrubber Area PLC Configuration Schneider-Quantum-140 CPU 652 60 02.40, No- 2 PLC’SSchneider-Quantum-140 CPU 652 60 02.40, No- 2 PLC’S

PLC-1PLC-1Digital IP-2M-64 I/ODigital IP-2M-64 I/OAnalog IP-2M-32 I/OAnalog IP-2M-32 I/ODigital OP-1M-32 I/ODigital OP-1M-32 I/OAnalog OP-2M-8 I/OAnalog OP-2M-8 I/O


Dry screen & Primary Area PLC Configuration Schneider-Quantum-140 CPU 652 60 02.40, No- 1 PLCSchneider-Quantum-140 CPU 652 60 02.40, No- 1 PLC


Schneider-Quantum-140 CPU 652 60 02.40, No- 1 PLCSchneider-Quantum-140 CPU 652 60 02.40, No- 1 PLC


Jozi power & Raw water Area PLC Configuration ModiconM340-BMX P34 2020 02.10, No- 1PLCModiconM340-BMX P34 2020 02.10, No- 1PLC


ModiconM340-BMX P34 2020 02.10, No- 1PLCModiconM340-BMX P34 2020 02.10, No- 1PLC

PLC-91PLC-91Digital IP-1M-16 I/ODigital IP-1M-16 I/OAnalog IP-2M-8 I/OAnalog IP-2M-8 I/O

Digital OP-1M-16 I/ODigital OP-1M-16 I/OAnalog OP-1M-4 I/OAnalog OP-1M-4 I/O

ProfiBus Communication module

ProfiBus Communication module ProfiBus Communication module Supporting for Schneider PLC’sSupporting for Schneider PLC’s

Baud Rate Support Up to 12,000 K Bit/SecBaud Rate Support Up to 12,000 K Bit/Sec

ProSoft Configuration

ProfiBus CommunicationProfiBus Communication

ProSoft Description TeSys T Protection Relay

Spider controller for Scrubber Spider controller for Scrubber

Siemens CP 342-5 for Cone Crusher Siemens CP 342-5 for Cone Crusher

Control Techniques Unidrive SP for VSD’s Control Techniques Unidrive SP for VSD’s

This all GS* files This all GS* files

All the above GS* files Communicated with Schneider PLC’s All the above GS* files Communicated with Schneider PLC’s

PLC Programming StructurePLC Programming StructureSequence logic was distributed in different Section Sequence logic was distributed in different Section known as the. known as the.

Analogs:A1061LIT6102.Analogs:A1061LIT6102. PID Loops:A1051FIC5126.PID Loops:A1051FIC5126. Drives:A1051PU15.Drives:A1051PU15. Valves:A1051XV5145.Valves:A1051XV5145. E.g. E.g. Analogs:A1061LIT6102 Analogs:A1061LIT6102 A1061- Area, LIT- Instrument, 6102- Number A1061- Area, LIT- Instrument, 6102- Number

PLC Programming StructurePLC Programming Structure

Sequences are known as the - Sequences are known as the - Sequence:SQPU038_STT.Sequence:SQPU038_STT. Sequence:SQPU038_STP.Sequence:SQPU038_STP. E.g. E.g. Sequence:SQPU038_STTSequence:SQPU038_STTSQ-Sequence, PU038-Pump Number, STT-StartSQ-Sequence, PU038-Pump Number, STT-Start

PLC Code StructurePLC Code Structure

PLC Code for Analogs

PLC Code for PID Loops

PLC Code for Drives

PLC Code for Valves & Sequences

PLC Code for inter PLC communication

BIT9A1012CV002BRS2FLT

BIT11A1012CV002BRS6A

BIT4A1012CV002BDS8A

BIT7A1021SB001_RUNUP

BIT12A1012ZSH1282

BIT14A1012ZSH1284A

BIT6A1012CV002BDS10A

BIT1A1012CV002BDS5A

BIT10A1012CV002BRS5A

BIT3A1012CV002BDS7A

BIT15A1012ZSH1284B

BIT13A1012ZSH1283

BIT5A1012CV002BDS9A

BIT2A1012CV002BDS6A

BIT8A1012CV002BRS2RLS

BIT0%S6 OUT

.31

BIT_TO_WORD16

BIT9A1021PU088_RUNUP


BIT4A1022CR003_RUN

BIT7A1022CR004_RUNUP

BIT12A1021PU090_RUN

BIT14A1012ZSO1293A

BIT6A1022CR004_RUN

BIT1A1012ZSO1285

BIT10A1021PU089_RUN

BIT3A1012ZSO1292A

BIT15A1012ZSO1294A


BIT5A1022CR003_RUNUP

BIT2A1012ZSO1291A

BIT8A1021PU088_RUN

BIT0A1012ZSH1284C OUT

.32

BIT_TO_WORD20

REAL_IN

BOOL3_INBOOL4_IN

BOOL1_INBOOL2_IN

INT_IN

PUB_OUT PLC1_EGD

FBI_230

COMMS_PUB22

BIT9A1022CV003_RUNDN

BIT11A1072CV010_SEQSTP_TPLC2

BIT4A1072ST002_AUTOSTT_HMI_TPLC2

BIT7A1022CV003_SEQRDY

BIT12

BIT14A1072ST002_AUTOSTP_TPLC2

BIT6A1072CV010_AUTO_TPLC2

BIT1A1072ST002_BELT_STT_TPLC2

BIT10A1072CV012_SEQSTP_TPLC2

BIT3A1072CV010_SEQSTT_TPLC2

BIT15A1023CV006_RUNUP

BIT13A1072ST002_BELT_STP_TPLC2

BIT5A1072CV012_AUTO_TPLC2

BIT2A1072CV012_SEQSTT_TPLC2

BIT8A1022CV003_RUNUP

BIT0A1072ST002_AUTOSTT_TPLC2 OUT

.1

BIT_TO_WORD17

BIT9A1021FIC2102_LLA


BIT4A1021SC001_RUNDN

BIT7A1022CV003_RUN

BIT12

BIT14

BIT6A1061PU045_SEQSTP_TPLC11

BIT1A1023CV006_SEQRDY


BIT3A1021SC001_RUNUP

BIT15

BIT13

BIT5A1061PU020_SEQSTP_TPLC11

BIT2A1021SC001_SEQRDY

BIT8A1021SC001_RUN

BIT0A1023CV006_RUNDN OUT

.2

BIT_TO_WORD21

CH1CH2CH3CH4CH5CH6CH7CH8CH9CH10CH11CH12CH13CH14CH15CH16CH17CH18CH19CH20CH21CH22CH23CH24CH25CH26CH27CH28CH29CH30CH31CH32

INT_Array

FBI_231

PUB_INT18

CH1TMWGCH2CH3CH4CH5CH6CH7CH8CH9CH10CH11CH12CH13CH14CH15CH16CH17CH18CH19CH20CH21CH22CH23CH24CH25CH26CH27CH28CH29CH30CH31CH32

REAL_Array

FBI_232

PUB_REAL19

Publish Data

PLC Code for inter PLC communication

Data_IN

INT_CH_3

INT_CH_31

INT_CH_28

INT_CH_22

INT_CH_25

INT_CH_19

INT_CH_16

INT_CH_13

INT_CH_7

INT_CH_10

INT_CH_4

INT_CH_1 A1022WQIT2229_RAWPV

INT_CH_32

INT_CH_29

INT_CH_26

INT_CH_23

INT_CH_17

INT_CH_20

INT_CH_14

INT_CH_11

INT_CH_8

INT_CH_2

INT_CH_5

INT_CH_27

INT_CH_30

INT_CH_24

INT_CH_21

INT_CH_18

INT_CH_12

INT_CH_15

INT_CH_9

INT_CH_6

FBI_1953

COMMS_INT4

RSTI

IP32IP422

IP110

Chn1DataPLC2_EGD

StartAddress1200

IP20

Data PLC2_DataComms_Dest PLC2_COMMS

AlarmChn1 PLC1R2_CommsChn1AAlarmChn2 PLC1R2_CommsChn2A

Alarm PLC2_CommsA

FBI_1927

COMMS_SELECT1

PUB_OUT

REAL_CH_3

REAL_CH_31

REAL_CH_28

REAL_CH_22

REAL_CH_25

REAL_CH_19

REAL_CH_16

REAL_CH_13

REAL_CH_7

REAL_CH_10

REAL_CH_4

REAL_CH_1 A1023WIT2329_PV_FPLC2

REAL_CH_32

REAL_CH_29

REAL_CH_26

REAL_CH_23

REAL_CH_17

REAL_CH_20

REAL_CH_14

REAL_CH_11

REAL_CH_8

REAL_CH_2 A1023WIT2339_PV_FPLC2

REAL_CH_5

REAL_CH_27

REAL_CH_30

REAL_CH_24

REAL_CH_21

REAL_CH_18

REAL_CH_12

REAL_CH_15

REAL_CH_9

REAL_CH_6

FBI_1952

COMMS_REAL3

Data_IN

BOOL_CH_3 A1072CV010_RUN_Comms

BOOL_CH_31

BOOL_CH_28

BOOL_CH_22

BOOL_CH_25 A1022CV004_RUN

BOOL_CH_19 A1021SC001_SEQSTT

BOOL_CH_16 A1022CV003_SEQSTT

BOOL_CH_13 A1072ST002_ILOC_FPLC2

BOOL_CH_7 A1072CV010_RUNDN_FPLC2

BOOL_CH_10 A1072CV012_RUNDN_FPLC2

BOOL_CH_4 A1023CV006_SEQSTT

BOOL_CH_1 PLC2_Watchdog

BOOL_CH_32

BOOL_CH_29

BOOL_CH_26

BOOL_CH_23

BOOL_CH_17 A1022CV003_SEQSTP

BOOL_CH_20 A1021SC001_SEQSTP

BOOL_CH_14 A1072ST002_IRDY_FPLC2

BOOL_CH_11 A1072CV012_RUNUP_FPLC2

BOOL_CH_8 A1072ST002_IRUN_FPLC2

BOOL_CH_2 A1071CV007_RUN_Comms

BOOL_CH_5 A1023CV006_SEQSTP

BOOL_CH_27

BOOL_CH_30

BOOL_CH_24

BOOL_CH_21

BOOL_CH_18 A1021SC001_AUTO_FPLC2

BOOL_CH_12 A1072CV012_SEQRDY_FPLC2

BOOL_CH_15 A1022CV003_AUTO_FPLC2

BOOL_CH_9 A1072CV010_SEQRDY_FPLC2

BOOL_CH_6 A1023CV006_AUTO_FPLC2

FBI_1954

COMMS_BOOL15

PLC2 received data

Data_IN BOOL_CH_33BOOL_CH_34BOOL_CH_35BOOL_CH_36BOOL_CH_37BOOL_CH_38BOOL_CH_39BOOL_CH_40BOOL_CH_41BOOL_CH_42BOOL_CH_43BOOL_CH_44BOOL_CH_45BOOL_CH_46BOOL_CH_47BOOL_CH_48BOOL_CH_49BOOL_CH_50BOOL_CH_51BOOL_CH_52BOOL_CH_53BOOL_CH_54BOOL_CH_55BOOL_CH_56BOOL_CH_57BOOL_CH_58BOOL_CH_59BOOL_CH_60BOOL_CH_61BOOL_CH_62BOOL_CH_63BOOL_CH_64

FBI_1955

COMMS_BOOL22

PLC2_DataPLC2_DataPLC2_DataPLC2_Data

Analogs & Drives Popup

AnalogsAnalogs Motors & PumpsMotors & Pumps ConveyersConveyers VSD’sVSD’s

PID Loops

Valves & Sequences

Presentation Prepared ByPresentation Prepared ByGHT GHT

Thanks for your attendance.Thanks for your attendance.

Documents

African Minerals Ltd