Gurpreet Singh Bhatia Mining & Material Handling ABB India...

Stockyard Management System An Integrated Approach for Better Efficiency

Gurpreet Singh Bhatia– Mining & Material Handling – ABB India Limited

© ABB Group April 19, 2016 | Slide 1

Stockyard Management Systems for Coal Fired Power Plants

PRESENTATION OUTLINE :-

Challenges in stockyard operation

ABB’s Stockyard Management System Feature

Material Tracking

Stockpile Mapping, Monitoring & Visualization

Quality Management

Fully Automated Stacking & Reclaiming

Other Features

SYMS Video

ABB’s Stockyard Management System – An Integrated Approach for Better

Efficiency

Reference

Stockyard Management System – Modules & Benefits

© ABB Automation GmbH April 19, 2016 | Slide 3

Challenges in Stockyard Operation & need for upgradation

Production Management Rarely connected to Process Data

Material Handling with vague quality accuracy

Interruptions in Operation due to faults triggered by operator failures or non-

availability

Dependence on Manual or Verbal Communication Methods during operations

“To increase production efficiency, to optimize the process

output and to reach an accurate input-output-balancing a high

grade of operator support and automation is necessary”


Reduced Stockyard

Efficiency

Stockyard Management System Features Material Tracking

Monitors the material flow of bulk material

Monitoring of masses/volumes on belt conveyors

Mass Balance for Monitoring

Tracking of materials to the discharge point

supplies real time stockpile tracking by tonnage and grade

Dynamic display of belt load with color differentiation according material type

Stockpile Monitoring

Calculated cuboid model and stacking model with scanner update based on

machine position, boom belt speed and tonnage

Comparison with the reality by 3D-laserscanner data


Stockyard Management System Features Stockpile Scanning Monitoring & Visualization

Stockyard Management System Features Stockyard Mapping Technology (in Collaboration with FL Smidth,

Germany)


Stockyard Management System Features Various Views of Stockpile Mapping



Stockyard management system features Quality Management

Takes over information from mine planning and geological modeling

systems or directly from transport group (train, ship, …)

Laboratory system integration for automated data of ore like Specific

properties, Grade of Ore, Moisture, Density etc.

Shows material origin and material owner

Qualities will be stored block wise for each transported material block,

starting at the receiving chute of a belt conveyor, along the belt

conveyor until it was spread onto the pile or loaded on a train/ship

Online Analyzers (NIR) Solutions

Ensures there is no material contamination

Data for reporting


Stockyard management system features Quality Management

Stockyard management system features Fully automated stacking & reclaiming (in Collaboration with FL

Smidth, Germany)

Fully automated reclaiming based on

stockpile shape and volume model

Operation supported by 3D laser scanner

for shape detection and RTK-GPS receivers

for exact positioning

Reclaiming also in worse environmental

conditions due to continuously updated

stockpile shape model

Smooth continuous operation reduces wear

and tear

Fully automated stacking assures the

execution of appropriate stacking method

(Coneshell, Windrow, ..)

Stacking exact into the specified stockpile

profile

Reduced dust by adjustment of the boom

close to the top of the pile


4-ABB Client Video.mp4


Stockyard Management by ABB – An integrated approach

Stockyard management Pile Monitoring

& Visualization

Material Tracking

& Visualization

Stacking /

Reclaiming

Technology

Quality

Management

Anti Collision

System

Electrification, instrumentation and automation Train loading

and unloading

Belt

conveyors Operational

level

Stacker/

reclaimer

Ship loader/

Ship unloader

Scanning/

GPS

Plant

Level

Collaborative Production Managament

ERP

Connection

Expert

Optimizer

Monitoring

Maintenance

Downtime Operations

Planning

Process

Information Management

Stockyard management system Operating &

dispatching

level

SEAMLESS INTEGRATION

LIMS

Knowldege Manager

Stockyard Management System by ABB

STOCKYARD

MANAGEMENT SYSTEM

(SYMS)

PRIMARY MACHINE AUTOMATION

3D MAPPING & UNMANNED TECHNOLOGIES

ERP/SAP INTEGRATION, HEADQUARTERS

SEAMLESS INTEGRATION

Stockyard management system Reference Effective Quality Management for Coal Fired Power Plants

An integrated coal quality management

system is in particular important in case

where power plants are supplied by

different mines with variable coal

parameters like Calorific Value, Density Ash

Content, Moisture Content, Sulphur,

Aluminum, Silicon and Potassium

The quality can be assured by blending the

coal on the stockyard during the stacking or

reclaiming process with methods like

Windrow, Chevron etc which are contained

in a control library and can be selected by

choice or automatically.

Automatic operation for the Stockyard

System of the Schleenhain Lignite mine in

Germany feeding the Lippendorf Power

Plant (2x993MWe). The stockyard system

as well as the belt conveyor systems are

operated fully automatic by an ABB 800xA

System from Control Room


Stockyard management system Modules and Benefits


Pile Mapping & Visualization

• Facilitate Better view for Operator

• Process Simplification

• Real-time update of Stackyard

Material Tracking & Quality

Management

• Real-time Quality Management for the entire yard

• Real-time Blending

• Online Material Tracking from loading

to discharge point

Unmanned Control Technology

• Manpower Optimization (One

operator for the entire yard

• Better utilization of machines and

energy management

• Accurate Stacking/Reclaiming

Integration with ERP/SAP

• Effective Planning

• Better Reporting/MIS Structure

• Automated Material Re-

conciliation

• Integration with other equipment

SYMS

Gurpreet Singh Bhatia Mining & Material Handling ABB India...

Documents

Transcript of Gurpreet Singh Bhatia Mining & Material Handling ABB India...