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NewsMining and Mineral Processing The official
user newsletter
|152
Contents
Cover story 1
Editorial 2
Technologies 3
Revamped portal accesses ABB’s insights to the mining sector 3
ABB Smart MinePower™ system to cut costs, boost electrical control at Kankberg Mine 3
ABB remote-control rock breaking system boosts mining safety and productivity 4
SmartMill™ brings advanced embedded control to grinding mills 4
Service and maintenance 5
ABB’s Hoist assessment service ‘Hoist Performance Fingerprint’ launches in North America and Mexico 5
Plant asset management service unlocks mine data to improve productivity 5
Process improvement services maximize efficiency of mining operations 6
Projects 7
ABB to help increase iron ore production at Poltava mine in Ukraine 7
ABB drive systems boost production at Canada’s Red Chris gold and copper mine 7
Events 8
Upcoming events and conferences 2015 8
COVER STORY
ABB & Boliden press trip shows how Next Level mining technologies lift potential of Swedish mine
seamless, efficient operation. ABB high-lighted its remote service expertise, with engineers in Switzerland constantly mon-itoring operations and on-call to ensure everything works as it should. This automation solution for Garpenberg, a region where mining began in the 13th century, demonstrates how technologies of the “Internet of Things, Services and People” are being deployed in under-ground mining. It’s also a stellar example of how we are implementing ABB’s Next Level strategy: intensifying engagement with existing customers, while expanding into new, high-growth market segments.Journalists visited from -1000 meters underground to 40 meters up into the hoist tower during the trip to Boliden’s Garpenberg.
From the control room of Boliden’s Garpenberg Mine, ABB’s System 800xA distributed control system helps opera-tors coordinate what once were stand-alone activities into an efficient integrat-ed systemABB worked with Boliden, a world-class metals company, to demonstrate to 20 journalists, some of whom had never been inside a working mine, how sophisticat-ed automation technology has created the world’s most advanced silver, zinc and lead mine. With ABB’s System 800xA control sys-tem, the Garpenberg Mine’s power dis-tribution and ventilation system can be monitored and controlled, while hauling, crushing and milling, once seen as dis-tinct tasks, have been transformed into a
International journalists on a press trip learned about ABB technology commissioned throughout Boliden’s Garpenberg, transforming it into the world’s most advanced underground mine.
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Mining and Mineral Processing News 2
Editorial
Giuseppe Di Marco Managing Director, Process Industries
Further info:[email protected]
Dear reader,
Setting the pace on securing the future of mining through integrated operations and advanced information technology is part of our vision. More connected equipment and devices and the information technology now produce more production informa-tion that can be used to significantly improve and optimize decision mak-ing across production outcomes. The combination of process automation and control, business intelligence, analytics and financial applications allows operations to integrate, analyze and refine this data.
But it’s not just new technology en-ablement that make the difference — it is also the people and the expertise behind it. Working together with our customers, partners and suppliers in a strong and long-lasting relationship remains the basis for our joint success today and in the future.
When combined, this “Internet of Things, Services and People” enables a new level of optimized operations and increased productivity and flexibil-ity, helping us to reach the next level in mining excellence.
We hope you enjoy reading this edition and discovering our new revamped web portal where enhanced content and features have been placed to maximize your experience.
Sincerely yoursGiuseppe Di Marco
Business-led collaborationMining means unlocking metals trapped in the earth and making them available for people to use. The challenge for Boliden is the metal it’s pursuing makes up a fraction of the rock it pulls from Garpenberg’s tun-nels. Of 2.5 million tons of ore processed annually at Garpenberg, just 15 percent is copper, gold, zinc, lead or silver; the remain-ing 85 percent can’t be used.Consequently, Boliden Chief Executive Offi-cer and President Lennart Evrell, who par-ticipated in the two-day tour of Garpenberg stretching from its 40-meter hoist tower to a kilometer below ground, turned to automation from ABB to wring more and more efficiency from his facilities as part of a $580 million expansion begun in 2011.
One intuitive interfaceABB’s 800xA now unifies the mine’s com-plex infrastructure into a single, intui-tive user interface offering comprehen-sive insight into what’s happening below ground — whether it’s the energy-saving SmartVentilation system, the new Smart MinePower solution that boosts reliability of remote-control rock-breaking system, due to be commissioned later this year. ABB has long been involved with mile-stones at Boliden, including commission-ing the first computerized mine hoist at its mine in Boliden, the Swedish gold-mining town that gives the company its name. In 2010, ABB installed its 800xA control solution at Boliden’s Aitik open pit mine.“Now, we have taken the technology even further - to the ‘Next Level’ of mining: Pro-viding the new mining infrastructure at Garpenberg means we have developed
Press release in English: http://bit.ly/1ISaoBm
More info on Next Level mining: http://new.abb.com/mining/next-level-mining
Follow us: http://twitter.com/abb_mining
one of the most efficient and safe under-ground mines in the world,” said Johan Söderström, Managing Director of ABB Sweden, who accompanied the journalists and ABB staff on the visit to the mine. ”The Internet of Things, Services and People makes it possible to create a safer, more efficient mine and build competitiveness for our customer.”From 33 work stations as well as mobile tablets, Boliden workers rely on ABB con-trols to oversee Garpenberg’s critical min-ing infrastructure.
Unique opportunityThe journalists came from Mexico, Ger-many, Sweden, Switzerland, the United Kingdom and the United States, places where the mining industry and its equip-ment suppliers can profit from ABB’s decades of experience in automating pro-cess industries.
Further info:[email protected]
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TECHNOLOGIES
Revamped portal accesses ABB’s insights to the mining sectorNew “ABB in Mining” website contains enhanced content and features to maximize user experience, providing easier access to essential information regarding mining industry trends as well as its mining products, systems, solutions and service.
New website: http://www.abb.com/mining
Press release in English: http://bit.ly/1IvfnEo
Recognizing website visitors are under ever increasing time constraints, the site overhaul reflects part of ABB’s ongoing efforts to make it quicker for profession-als to access what they need and to en-gage more effectively with ABB. To that end, mining menus are streamlined and content consolidated to make it more straightforward for users to find and to differentiate between ABB’s industry thought leadership viewpoints versus its practical applications as a mining spe-cialist provider.Information on new products, events around the world and global case
studies, often brought to life in a rich multimedia format including videos, animations and infographics, will be added continually. By accessing the site regularly, users will be able to keep up to date, efficiently, on current “hot topics and trends” related to mining and mineral processing as well as learn more about ABB contributions to these issues. “This is a key milestone within ABB’s mining communication strategy,” says Emmanuel Chabut, Head of Communi-cation for ABB’s Process Industries Business Unit. “Not only have we im-proved the user experience, but the new
structure enables us to keep continually expanding our online content in an easy to navigate format. The improvements will help our readers to remain the best informed professionals in the mining sec-tor for the least amount of effort.”
Further info:[email protected]
A new web focus on the mining “value chain” While the new “ABB in Mining” web site’s improved navigation functionality still allows readers to search for infor-mation through traditional categories such as products, systems, solutions and services, visitors can now browse material via the main steps in the mining value chain such as:
– Open-pit or underground operation– Crushing and conveying– Grinding– Processing and refining– Transportation to market.
ABB Smart MinePower™ system to cut costs, boost electrical control at Kankberg MineABB has been awarded its first order for the newly developed ABB Smart MinePower™ system from Boliden for its Kankberg Mine in Sweden. This intelligent power management solution for complete underground mine power distribution will optimize and strengthen the power supply while accelerating maintenance and boosting safety.
The order includes an energy-saving Resibloc EcoDry transformer, MNS switchgears with TMax XT distribution
groups and mSpeed VSD groups with ACS850 drives. The system is based on a modular
concept for mobility, flexibility and easy expandability and can be remotely moni-tored and controlled when integrated with ABB’s System 800xA. It also uses fuseless technology and safe-with-earth fault protection and arc guard. Func-tions include supervision and control of protection settings, alarm management, dynamic selectivity planning, selectivity
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supervision, improved maintenance and operator assistance, fault tracking and localization. “ABB’s new Smart MinePower™ technol-ogy is an ideal power management solu-tion for underground mines, facilitating energy measurement and optimization,” says Peter Terwiesch, President of ABB’s Process Automation division. “It will help to solve many efficiency-related chal-
lenges in existing mines and will increase safety for the entire operation, setting the standards for future projects.”
Further info: [email protected]
Press release in English: http://bit.ly/1IMPjnk
ABB remote-control rock breaking system boosts mining safety and productivity ABB is supplying a remote control rock breaking system for Boliden’s Garpenberg Mine, deploying technol-ogy of the Internet of Things, Services and People to boost safety and pro-ductivity in underground mining.
The project includes two ABB remote control stations as well as process and safety controllers, all of which are being integrated along with a real-time video system into the ABB System 800xA automation platform. The 800xA will inte-grate rock breakers and their hydraulics within Garpenberg’s unified system of mill drives, hoists, ventilation and crushing equipment, coordinating what had been fragmented sub-operations into seamless tasks. All fixed equipment can now be controlled from the same control system, ensuring safety and boosting efficiency.“ABB’s remote control technology will make the operation of the rock break-
ers safer and more efficient by enabling operation in a remote station above the ground during blasting and shift chang-es,” says Patrik Westerlund, product manager for underground mine automa-tion at ABB. “The modularized design will also allow Boliden to add more rock breakers as the mine expands by simply adding another ABB remote control sta-tion to the network.”
The project will be commissioned during the second half of 2015.
Further info:[email protected]
Press release in English: http://bit.ly/1Hvji2n
SmartMill™ brings advanced embedded control to grinding mills
Press release in English: http://bit.ly/1UcQqTy
This advanced predictive control solution, embedded within a variable-speed drive, will harness multiple variables such as feed rate, rotation speed, and mill load to greatly improve productivity and efficiency.
Traditionally, operators face limited flex-ibility in optimizing grinding operations, and adjustments are usually performed with only rudimentary control automa-tion, or none at all. ABB’s SmartMill provides continuous control of individual grinding mills, optimizing the process by adapting the actual mill speed and
feed rate to current conditions in real time. The speed is varied according to an advanced control concept that keeps the mill solid feed as high as possible while monitoring signals such as power consumption, motor torque and bearing pressure, and mill speed.SmartMill provides full stability to indi-vidual mills, without the need for addi-tional controllers or sensors. This leads to increased grinding efficiency, reduced energy consumption, higher throughput, better influence over particle size, fewer shift-to-shift variations and extended liner lifetime.
“Normally, there is always a trade-off between particle size, throughput and recovery,” says Marcelo Perrucci, Global Product Manager, ABB. “SmartMill al-lows flexible adjustments so that the sweet spot, which will vary from mine to mine, can be readily identified.”
Further info:[email protected]
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SERVICE AND MAINTENANCE
ABB’s Hoist assessment service ‘Hoist Performance Fingerprint’ launches in North America and MexicoThe structured and customized concept of Hoist Performance Fingerprint helps mining customers reduce maintenance costs and improve safety and asset performance. First launched in Australia, Sweden, and South Africa, ABB’s second roll-out focuses on the strong underground mining markets of Canada, USA and Mexico.
system, we offer our customers a com-prehensive service solution from a single source. This holistic concept is unique in the underground mining market.”A mine hoist system is an intensive and important carrier in the mining process. It is not only essential to keep produc-tion running, it also transports mining staff below ground. Therefore, its reli-able and safe operation is key for mine
operators, particularly, as many coun-tries have special legislative require-ments in place defined by the respective mining authorities. The expert concept of the new Hoist Performance Finger-print ensures that all these requirements are met, allowing customers to focus on their daily business.
Further info:[email protected]
Hoist Performance Fingerprint helps customers assess and optimize the condition of their mine hoists. It con-sists of a structured audit of complete hoist systems — covering all electrical and mechanical parts to ensure reliable and safe hoist operation. It is a consult-ing and audit service developed and performed by highly experienced ABB service experts. The entire hoist system is assessed, analyzed and tested using high quality data collected from over 20 pre-defined points and a structured tailored analysis tool. This data forms the backbone for any further analysis done after leaving the site. All results, findings as well as corresponding rec-ommendations for optimizations and improvements, are then presented to the customer in a detailed report for follow-up.“The Hoist Performance Fingerprint is a cost-effective service that provides diagnostics, key findings and recommen-dations in less than a week,” said Remy Lanoue, Global Service Manager for ABB’s Process Industries business unit, “By assessing and analyzing all electri-cal and mechanical parts of the hoist
For more information about this product: http://new.abb.com/mining/services/hoist-performance-fingerprint
Press release in English: http://bit.ly/1KUoGRn
Plant asset management service unlocks mine data to improve productivityAssetVista™ offers mine operators a complete overview of their produc-tion assets’ condition, helping opti-mize production time and minimize maintenance. This scalable solution will sustain and improve maintenance performance of a mine by easily accessing previously untapped asset data and compiling it efficiently.
The AssetVista solution unlocks an integral feature of ABB’s long-established System 800xA platform Asset Optimi-zation. However, it can be also easily
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integrated in a range of other third-party control systems. To work most effec-tively, AssetVista is combined with the customer’s maintenance management. This combination improves equipment reliability, thereby reducing maintenance and operational costs, avoids unplanned shutdowns and increases productivity.By pulling together previously disparate condition data from various assets, such as valves, switches, sensors, motors, switchgear, gearboxes, crushers and conveyors, AssetVista collectively analyz-es and compares all data, enabling users to define a thorough predictive mainte-nance strategy. A critical analysis of each asset, equipment or component takes
into account failure modes, available control system data, as well as informa-tion from pre-installed expert condition monitoring systems and datasheets.“AssetVista™ breaks down the informa-tion silos that exist between operation, automation and maintenance personnel, by having them share the same knowl-edge,” says Giuseppe di Marco, Manag-ing Director of ABB’s Process Industries
business unit. “This smooth integration of data leads to increased operational efficiency through faster repairs and the elimination of unnecessary maintenance that might expose personnel to safety risks.”The product was launched in Brazil, Peru and Chile, with other countries to follow.
Further info:[email protected]
PRISE maximizes efficiency of mining operations
Press release in English: http://bit.ly/1Ma4CMi
For more information about this product: http://new.abb.com/mining/services/assetvista
Video: http://youtu.be/Ap5sQTb-4sM
Expert asset condition and maintenance management solution
Customer concerns– Demand for reduced maintenance and operation costs while increasing
productivity– Need for improved equipment reliability and reduced unplanned shut-downs
Our solutionsA scalable approach that leverages existing equipment data to optimize and sustain your maintenance performance.
Features– Proven maintenance methodologies implemented Asset monitor library with
demonstrated results– User-friendly and maintenance-oriented dashboards and periodic reports– Built on plant asset management solution 800xA Asset Optimization
Benefits– Increased operational efficiency through elimination of unnecessary
maintenance and improved time to repair– Break up of information silos between operation, automation and maintenance
personnel ensuring smooth integration
The new service called PRISE — Process Improvement Services — provides a systematic approach to identify performance gaps in open-pit mining processes and provides solutions to optimize processes in a permanent way, maximizing productivity, improving product quality, and preventing waste.
As plants become more and more auto-mated, plant operators are required to monitor multiple complex processes and predict and control their behavior based on an overwhelming amount of data. The PRISE packaged offering removes the problem of operator overload by provid-
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ing essential information, while steering all processes in an optimal way.To set the foundation for increased per-formance, ABB experts will analyze the existing process, identify missing instru-mentation, and correctly tune critical PID loops. The centerpiece of the service is advanced process control to first stabi-lize processes, then drive them to their
performance limits in a consistent and permanent way.“Reducing variances, while pushing the process to its limits, is not something a human being can accomplish in the same way PRISE can,” said Dominik Groenveld, Global Product Manager for PRISE. “PRISE eliminates shift to shift variations by permanently and smoothly
Press release in English: http://bit.ly/1PxSdkS
controlling plant processes at optimal levels — at all times and in all situations.”
Further info:[email protected]
PROJECTS
ABB to help increase iron ore production at Poltava mine in UkraineState-of-the-art ring-geared mill drive solution to provide process efficiency and equipment reliability for Ferrexpo Poltava Mining’s latest mine upgradeABB will deliver a low-speed, dual pinion ring-geared mill drive system (RMD) for the Poltava mine expansion in Komso-molsk, Central Ukraine. This solution will help increase the capacity of the mine’s processing plant. With its maintenance-friendly design the RMD solution minimiz-es mechanical wear on ring-geared mills and reduces downtime and repairs, while providing high availability of the grinding equipment.The complete RMD system comprises two 4.5MW synchronous motors, an ACS 6000 multi-drive, converter transformer and ABB’s advanced integrated mill controller. By operating on low-speed, with motors driving the pinions directly, no gearboxes are required. For smooth operation and ease of maintenance, the RMD comes with inherent features and functionalities such as variable-speed, frozen charge protection, the frozen charge remover function, controlled roll-back and automatic positioning.
Deliveries are scheduled for October 2015 with estimated start of operations in 2016. Ferrexpo Poltava Mining has an estimated 3.6 billion tons of resources coming from two iron ore deposits located within the largest iron ore body in Europe. The tradi-tional shovel and truck operation extracts approximately 30 million tons of crude ore per year. The mine upgrade will increase
the production from 10.8 to 12 million tons of pellets per year and extend cur-rent over 40-year mine life until 2038.
Further info: [email protected]
Press release in English: http://bit.ly/1DY5pYU
ABB drive systems boost production at Canada’s Red Chris gold and copper mineCopper concentrate throughput at Imperial Metal’s greenfield project exceeds projections after installation of two reliable low-speed dual pinion ring-geared mill drive systems (RMD’s) at the Red Chris gold and copper mine in Vancouver, Canada.
Imperial Metals, an exploration and min-ing company with expertise and focus on base and precious metals, required a
drive solution that could accommodate a planned mill rate of 30,000 metric tons per day over the mine’s expected lifetime
of 28 years. They chose ABB to supply the robust RMD solution because of its proven reliability. Commissioning began in November 2014 and was success-fully completed, with both RMD systems operating at 100 percent load in Febru-ary 2015. “We are very pleased with ABB’s com-
8Mining and Mineral Processing News
We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents — in whole or in parts — is forbidden without prior written consent of ABB Switzerland Ltd.© Copyright 2015 ABB. All rights reserved
For more information please contact:
ABB Switzerland Ltd.Mining and MineralsSegelhofstrasse 9PCH-5405 Baden 5 DättwilSwitzerlandPhone: +41 58 586 84 44E-mail: [email protected]
ABB’s Mining business is represented in the following countries: Australia, Brazil, Chile, China, Germany, Canada, Peru, South Africa, Sweden and Switzerland.
For contact details, please visit our website: www.abb.com/mining
EVENTS
Upcoming events and conferences 2015
20–24 September SAG Conference, Vancouver, Canada Further info: [email protected]
21–25 September Perumin, Lima, Peru Further info: [email protected]
4–6 November ABB Automation & Power World, Delhi, India Further info: [email protected]
mitment to complete the project execu-tion and final commission of the equip-ment,” said Tim Fisch, general manager at Red Chris. “We have been able to produce our first copper concentrate with a much higher throughput rate than originally planned at this point of the startup thanks to the excellent ABB proj-ect and commission team from Canada and Switzerland.”ABB’s complete scope of supply in-cluded two dual pinion low-speed mill drive systems for a 34 foot 2x5.2 MW semiautogenous (SAG) mill and a 24 foot 2x7 MW ball mill, engineering and
Press release in English: http://bit.ly/1gi9PW7
Animation: http://youtu.be/WNXuI2kFoYI
commission. The drive systems are comprised of transformers, ACS 6000 MV frequency converters, synchronous motors, advanced mill control, opera-tions and maintenance features inherent to the ABB RMD solution.
Further info:[email protected]
