MineOptimizeMichel Serres, ABB Canada, VP Mining Solutions NAM

An Automation Platform

© ABB Group

November 30, 2016 | Slide 2

The mining industry today The main challenge

• Standardization of processes

• Mechanization means dramatic shifts

in production capabilities

• Operation of equipment still requires

human interaction

• Integrated modeling and planning for

higher quality yield

• Greater visibility into parts of the value

chain

• More detailed information coming

from equipment and plant to enable

remote mining

• Reduce total ownership cost

• More responsive demand and supply

• Higher level of automation driven by

labor shortages and remote locations

• Limiting bottlenecks by adopting more

continuous processes

• High levels of visibility across the

value chain and between operations

Mechanization Automation Optimization

Five key

mining industry

requirements

• Productivity

• Safety

• Sustainability

• Reliability

• Environment

© ABB Group

November 30, 2016 | Slide 3

The mining industry future Attractive changes moving forward

Reduce cost, increase productivity, and safety by

remote monitoring, diagnostics and interventions

Move automation and electricity to where the

ore is extracted, minimize haulage, and transport

… people further away from processes … equipment closer to processes

Key features of future mining operations

Limited human presence in production area

Continuous production and mechanical excavation

Central control room

Continuous availability of ore, people, and equipment

The traditional way Remote monitoring of equipment, preventive maintenance

The traditional way Underground electricalsand autonomous equipment

… enabled by integrated operations from pit to port, fully automated, and remotely controlled

© ABB Group

November 30, 2016 | Slide 4

MineOptimize

System Engineering

Electrification & Automation

Power & Process Control

Collaborative Production Mgt.

The people, engineering expertise and

a century of knowledge and know-how

of electrification and process control in

mining

Integrated portfolio of products,

solutions and services to optimize

customer investment and process

productivity

Ability to Integrate third-party

application within an Automation

Platform, linked applications, data

correlation and data treatment.

Mining know-how

© ABB Group

November 30, 2016 | Slide 5

MineOptimizeIntegrated value chain from pit to port

Energy

Management

Wireless

Location Intelligence

Hoist, Ventilation,

Mine Planning

Dispatching &

Scheduling

Central Control

Room, ERP, CMSS

Grinding, GMD,

RMD, APC

Conveyor Belt

Control

Electrification

Solutions

Condition

Monitoring

Ship Load &

Unload Control

Flotation, APC,

Instrumentation

Stockyard

Control

Substation

Control

Drives

Solutions

High levels of visibility across operations

ABB Mining Solutions An Automation Platform approach...

https://www.youtube.com/user/abbmining

© ABB Group

November 30, 2016 | Slide 7

MineOptimize Automation SolutionOne power and process system approach

Integrated 800xA

process control and

power automation

Enable power &

process control and

integrated mine

operation

Improves information flow

and visibility across

organizational silos

Process and electrical

control software,

HMI displays

• Separate systems for different

parts, networks, servers,

teams, spare parts

The MineOptimize way

The traditional way

Integrated E&I device

monitoring and

configuration

Remote operation,

maintenance and data

access

Alarms and events,

audit trails

historical data,

trending

MineOptimize

© ABB Group

November 30, 2016 | Slide 8

MineOptimize Advanced Process ControlProcess optimization according to ore properties

Model predictive

control engine

integrated into control

system

More metal ore is

recovered

Higher equipment utilization,

increased recovery and

lower energy consumption

Real time ore

analyzer detects or

Mine Planning

application, changes

to ore grade

• No information on upstream

downstream impact

• Can’t prioritize significant data

volumes

The MineOptimize way

The traditional way

Predictive

adjustments made to

mining grinding

Plant react to ore

variability ahead of

time

Real time operations

reports changes in ore

properties

MineOptimize

© ABB Group

November 30, 2016 | Slide 9

MineOptimize Scheduling & DispatchingJust-in-time optimal process management

Personnel, mobile and

fix equipment

integrated into control

system

Operations team

working in the

optimum level

High degree of automation

and information access

enables safety and

production as per plan

Mine operators

schedule, dispatch

and track operations

in real time

• No information about the

location and status of

mobile/fixed equipment

• Cannot prioritize works plans

and loading sequences

The MineOptimize way

The traditional way

New task plans and

loading sequences

are calculated and

executed

Production analyses

and statistics can be

retrieved on-line

Mobile and fixed

equipment report local

conditions, task status

and location

MineOptimize

© ABB Group

November 30, 2016 | Slide 10

MineOptimize Condition MonitoringReact to asset condition in real time

Asset management

integrated into control

system

Reduces losses due

to equipment failure

Reduce maintenance costs

while improve equipment

reliability and reduce

unplanned shut-downs

Asset monitor detects

condition

• Reactive maintenance

• High operating costs

• Unexpected breakdown of

critical assets

• Catastrophic impact on

production targets

The MineOptimize way

The traditional way

Work order with site

maintenance crew is

raised automatically

Maintenance and

operation responds

ahead to reduce

failure risk

Predictive

maintenance alarm

is triggered

MineOptimize

© ABB Group

November 30, 2016 | Slide 11

MineOptimize Information ManagementMake goal-oriented decisions

Single information

platform integrated

into control system

Targets achieved

based on transparent

information

Make the right decisions

based on consolidated,

consistent and transparent

information

Automated data

collection,

consolidation and

calculation

• Manual data collection and

calculations

• Information available in

segregated documents

• Difficulty to identify differences

among multiple sources and

versions

The MineOptimize way

The traditional way

Consistent distribution

of information at the

plant and corporation

Information

empowering goal-

oriented decisions

Report process,

production, energy

and maintenance

KPIs

MineOptimize

Integrated Mining OperationImprove visibility, planning and real-time coordination

Improve operations

visibilityBy providing complete, accurate and timely data

Improve coordination

between functional silos

By providing better visibility and real-time management

system integration

Support improved

production rates and

throughput

By providing better planning capabilities to minimizes

bottlenecks

Reduce hazard

exposure

By removing people from hazardous environments

through better information and communications systems

Top benefits How we can help

Enterprise Software

ABB Automation Platform

ABB Mine Optimize

ABB Mining Solutions An Automation Platform approach...

ABB Confidential

© ABB Group

November 30, 2016 | Slide 14

The future of mining – extended automationBringing things, services and people together

Mine Smelter

Minerals / Metals

price volatility

Sales / Contracts

Corporate headquarters

Loading

and transport

Ore hoist

and feeding

Grinding Thickening FlotationCrushingDrilling,

charging

and blasting

Dryer Furnace ConverterFiltering

Ore feeder

Concentrate

transport

Electrification

Transmission

& Distribution

E-houses MCC &

Drives

Concentrator

ABB Mining SolutionsSolution Integration

Slide 16© ABB

ABB Mine Location Intelligence™

In cooperation with Boliden and MobilarisNovember 30, 2016

Increased safety and productivity

First level

Second level

‒ Third level

‒ Fourth level

‒ Fifth level

‒ Fifth level

Enabled by mine wide wireless communication network through WLAN (or future 5G)

3D visualization on a map Connection of people and machines

2013

John locates Tore in the

map and selects his icon

Locate People and send them a message

Boomer L2C MBR 19

FAILING

Drilling at face L25

Drilling at face L27

Drilling at face L28

Find equipment and problems

Equipment data can be integrated into maps

John starts sending Tore

a message about the

problem

Find who is closest to a problem

Find people and solve problems

21

Enter Alert text

Enter Notification text

Greate Geofence

Place markers

Create Geofence

Submit Message

Warning! Road 11 is blocked by a truck with

an engine failure. Take alternative route at

Road 700

Warning, road block ahead!

In order to redirect the traffic,

Bruce quickly creates a

geofence

Messages are generated when you enter a Geofence

Traffic Management and Geofencing

Slide 22© ABB

Rock Breaker

November 30, 2016

Remote Control Operation

Reducing unnecessary risk and travel time

Remote control desk Slave arm

Automated scheduling

November 30, 2016

Short term scheduling in closed loop

Increased utilization of machines and faces

A predictive production from the beginning of the value chain

Real-time visualization of actual status and on-line replannng

Executor

Scheduler

Monthly production plan

Personell and machine availability

Machine characteristics and distances

Work list Progress list

Progress of workWork orders

Connected to all mobile machines

Integrated Mine OperationsEnforcing operational KPIs

Enforce schedules that keep KPIs within bounds

Schedule work order execution so

as to keep the process within

bounds

Examples

Water and Power Constraints

Blend parameters

Ore origin

Trip length

Production rate

Same framework can be used to

manage of other limiting factors

such as capacity of maintenance

crews or fueling stations

without / with KPI bound enforcement

Integrated Mine OperationsEnforcing operational KPIs

Enforce schedules that keep KPIs within bounds

Schedule work order execution so

as to keep the process within

bounds

Examples

Water and Power Constraints

Blend parameters

Ore origin

Trip length

Production rate

Same framework can be used to

manage of other limiting factors

such as capacity of maintenance

crews or fueling stations

without / with KPI bound enforcement

The Internet of ThingsABB things

Smart, communicating devices by ABB

The Internet of Things (IoT) is the network of

physical objects or "things" embedded with

electronics, software, sensors, and network

connectivity, which enables these objects to

collect and exchange data [1]

The Internet of Things allows objects to be

sensed and controlled remotely across

existing network infrastructure [2]

Things Robots Motors

Switchgear Controllers

[1] "Internet of Things Global Standards Initiative“, [2] https://hbr.org/resources/pdfs/comm/verizon/18980_HBR_Verizon_IoT_Nov_14.pdf

© ABB Group

November 30, 2016 | Slide 27

Mine network architecture

Data Center(s)

Tier 3: Site Local Area NetworkWired Ethernet for Connected Devices

Tier 1(Core)

Mine operation, connectivity, and

applications

Tier 2(FAN)

Tier 2: Field Area Network (FAN)Point-to-Multipoint (PTMP), Mesh, Cellular

Tier 1: Core IP NetworkFiber, Point-to-Point (PTP) Microwave, PTMP

DHCP

AAA

Firewall

Tropos

Control

VPN

Network

Management

Network Services

and Security

Fix

ed

an

d M

ob

ile C

om

mu

nic

atio

n S

erv

ices

IDS

DNS

Wired

Wired

Wired

Video

Security

SCADA

Asset Health

Fleet Management

Tier 3(Site LAN)

Enterprise Information Services

GIS

VoIP Email Other

SCADA

Endpoints

VoIP

Phones

Video

Cameras

Trucks,

excavators,

bulldozers

Laptops,

Tablets and

Smartphones

1. One control room

2. No human presence in the production areas

3. Continuous mechanical excavation

4. Pre-concentration

5. Resource characterisation -mineralogy

6. Resource characterisation –structural control

7. Final products

8. Attractive work places

A picture of the future mineProgress

Source: RTC SMIFU report

Autonomous industrial mobile manipulation system

*In cooperation with Boliden, LKAB, NCC, Orica, RTC and Atlas CopcoNovember 30, 2016

Safer charging*

40% of all accidents happens in the charging

operation

Concept done – prototyping design to start

Move personnel from unsafe areas through increased automation

Manual work in high risk area Remote manipulation of complex task

Securing the future of miningAn Automation Platform

ABB portfolio provides visibility and

optimization across the value chain

ABB products and systems drive

fundamental change in the way a mining

enterprise works, creating increases in

Process productivity

Predictability of operations

Asset reliability

Energy efficiency

Health, safety

Protection of the environment