Solution architectures for MINERAL PROCESSING PLANTS
Transcript of Solution architectures for MINERAL PROCESSING PLANTS
MINERAL PROCESSING PLANTS
Solution architectures for
Solution architecture for processing plantsOur integrated solution reduces cost per ton, and directly impacts your bottom line
Production costs
Maintenance costs
Other fixed costs
Invested capital
OEE
OBJECTIVE:Reduce cost
per ton
OBJECTIVE:Maximize
shareholder returns
Material produced / sold
Average commodity price
Sustainability
Earnings before
interest and taxes
(EBIT) Return on capital(ROCE)
Operating costs
COSTS
RevenueAvailability -
Performance -Product quality -
Smart devices predict potential failures and increase uptime
Innovative motor management solutions deliver faceplate performance for communution circuits
Model predictive control strategies enable optimum particle size and recovery
Optimization solutions reduce use of energy, water and reagents
Integrated Architecture across the processing plant is easier to troubleshoot and quicker to repair
Operator-centric solutions reduce training costs and enable better knowledge transfer
Reagent costs - Grinding media -
Energy cost -
Operating working capital (inventories, cash) - Net plant, property and equipment -
Rehabilitation provision -
Safety -Water -
Land -Air -
People - Training -
Offices -Depreciation -Government -
royalties
Repair and - maintenance
labor
2Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
Simplified architectureREMOTE MONITORING
FLOTATION CAMERA
LV MOTORS LV MOTORS
CROSSBELT ANALYZER
SUBSTATION CRUSHERS GRINDING FLOTATION THICKENER
LV MOTORSLV MOTORS LV MOTORS MV MOTORS
IEC 61850
3Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
REMOTE MONITORING
FLOTATION CAMERA
LV MOTORS LV MOTORS
CROSSBELT ANALYZER
SUBSTATION CRUSHERS GRINDING FLOTATION THICKENER
LV MOTORSLV MOTORS LV MOTORS MV MOTORS
IEC 61850
Intelligent Packaged Power:A unified power and process control
architecture allows for increased operational visibility and reduced
maintenance costs.
ControlLogix® Process Controllers:Redundant controllers with
redundant network topology for high availability applications.
PowerFlex® Low Voltage and Medium Voltage Drives for Crushers:• Deliver continuous choke feeding
of the crushing chamber for optimal productivity
• Maximize starting torque and enable crusher restart with material still inside the chamber (reducing stoppage times)
• Premier Integration with control systems
Dynamix™ Integrated Condition Monitoring System: Dynamically monitor sensor information (vibration, speed, etc.) to identify potential equipment issues
before failure occurs. Offers configuration in any Allen Bradley® ControlLogix® controller.
Industrial Data Center:Redundant, virtual data
management that comes with remote support services and
helps you keep your infrastructure running efficiently.
Process Control for Mining:• Pre-engineered content for mining control, monitoring,
and reporting that’s built on our standard PlantPAx® Distributed Control System. Includes mining-specific applications such as dedicated control strategies for flotation level control.
• Simplify programming, configuration and maintenance of controllers and field devices with unified tools.
• Premier Integration with drives.ThinManager®: Centralize and simplify management of applications and visual sources.
FactoryTalk® InnovationSuite: Remotely monitor assets, predict equipment failure, and identify improvement opportunities.
E+H FieldCare:Configure and manage intelligent field devices – simple device configuration, maintenance management, condition-based maintenance and lifecycle management.
FactoryTalk® OperationSuite:Use Model Predictive Control strategies to gain a level of intelligence above your process control that helps reduce variability, improve product recovery, reduce reagent consumption, reduce energy costs, and increase throughput. Available as software based or in chassis.
Converged Plantwide Ethernet Architectures:Tested and validated reference architectures co-developed by Rockwell Automation and Cisco enable IT/OT integration, quality performance and security at every level.
Open EtherNet/IP Network Across All Levels:Reduce engineering and maintenance costs by securely integrating devices like your MCC, I/O, field instruments, and other third-party devices over an EtherNet/IP Network.
FactoryTalk® Analytics™ LogixAI™:Use an embedded artificial intelligence module to find optimizations at the operation level, with no data scientist required.
FactoryTalk® InnovationSuite: Use augmented reality technologies to gain real-time equipment operating and performance information, as well as enable collaboration for equipment maintenance.Field Instrument Integration:
Reduce programming, reduce configuration errors, and increase productivity with field instrument integration from Rockwell Automation and Endress+Hauser.
IntelliCENTER® with EtherNet/IP:Streamline setup and enhance visibility between process and motor controls. Use network connectivity to quickly monitor, troubleshoot and diagnose issues with your motor control center.
PowerFlex® 7000 — Medium Voltage Solutions for Mill Applications (up to 34,000 Hp):• Easy and fast power connections • Master-follower configuration• Premier Integration with Logix control
platform to simplify parameter and tag programming and reduce development time
• Supports higher elevations/altitude and ambient temperatures
• Enables the use of existing motors
4Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
USE CASE
Mine-wide process control systemStandardizing operation and control between process areas: Iron ore mining / Brazil
The control system is split in four parts: the mine and the concentration plant, the pipeline, the filtration plant, and the port.
The control system has more than 20,000 instruments and is connected with 800 motors. Among them, more than 1500 intelligent instruments are connected to the system via PROFIBUS PA or HART.
The asset management system, implemented in all parts of the distributed control system, facilitates the parameterization of intelligent instruments.
Powerful reporting capabilities including water management, production vs. energy consumption, management of motor use, among others, allow for optimal resource use.
At the end of the project, the user made their first shipment of ore ahead of schedule and at a lower cost than expected – with the Rockwell Automation distributed control system contributing to its success.
Delivering ore ahead of schedule and at a lower cost.
5Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
SOLUTION AT A GLANCE
Flotation level controlLevel control of highly coupled flotation cells in series
Builds an internal response model for each individual cell allowing for fast initial changes to input disturbances – minimizing disturbances.
• Fast response to disturbances
• Adaptive control that accommodates deteriorating valve performance
• Reduced dependency on specialized software and expert engineering labor
• Consistent level control for better optimization of other variables such as air and reagent addition
• Logix®-based control allows for fast integration and high availability
• Native operational settings and diagnostics available
• Can be incorporated with advanced process control techniques like model predictive control
BEFORE
AFTER
6Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
Standardized configuration• Standardization of module configuration• Reduces programming and configuration errors
Asset management integration (FieldCare)
Connect and monitor field devices regardless of their physical or network location
Powerful network integration• Ethernet/IP native instruments• HART• WirelessHART• PROFIBUS PA• Foundation Fieldbus
Integration documents• Application overview• Recommended hardware/software specifications• Preferred steps for integration• How to install and connect • Configuration of Rockwell Automation input modules• Configuration of E+H measurement components• Visualization
Pre-engineered faceplatesGraphical representation for
operator workstations
REDUCED INTEGRATION COSTS AND FEWER RISKS
FASTER COMMISSIONING
REDUCED MAINTENANCE COST AND STRESS
SOLUTION AT A GLANCE
Integration with E+H process instruments
7Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
Optimal control of iron ore flotationBuilds an internal response model for each Pellet feed concentration
• On average, 100 gr less amine was used per feed SiO2 ton yielding significant USD savings
• Allowed the customer to step up production of the most valuable concentrate type from 46% to 73% on average
USE CASE
Process optimization
BEFORE MPC AFTER MPC
8Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
SOLUTIONS AT A GLANCE
Integrated motor control for comminution
Benefit from heavy-duty ratings which provide 100% of the rated current
continuously, 150% of rated current for one minute, and 180% for three seconds.
Reduce downtime caused by mechanical issues by automatically identifying and suppressing harmful resonance and vibration conditions using adaptive
tuning, enabled by TotalFORCE® Technology.
Continuously monitor operation and remaining life of components based on actual operating conditions. Avoid unexpected downtime caused by component failure with predictive maintenance capabilities, enabled by TotalFORCE® Technology.
Continuously monitor and adjust for normal crusher mechanical wear as needed to maintain production with load observer, enabled by TotalFORCE® Technology.
Precisely control speed and torque, with high-performance
motor control enabled by TotalFORCE® Technology.
Control for disturbances by ‘throwing out’ isolated
crusher disturbances from drive system data and
eliminating unnecessary output adjustments.
Gain higher reliability and maximum uptime with a modular
design that has low component count and low electronics failure rate. Switch a cell from our drive
solution in just a few minutes.
Leverage motor-friendly waveforms to retrofit existing
motors with existing motor cables on our medium voltage
drives – no need for inverter duty motors.
Reduce troubleshooting and unplanned downtime with powerful motor diagnostics gained through advanced networked motor control and protection.
Reduce engineering and commissioning costs with Premier
Integration, which provides a simplified integration experience
when configuring drive operation and control into the Logix environment.
Includes design productivity, controller-based safety, application
code manager, Automatic Device Configuration, mobility and
visualization, and analytics.
Master follower configuration
9Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
SOLUTIONS AT A GLANCE
Premier integration between power and control
Master follower configuration
Accelerate project engineering with a suite of pre-engineered control and HMI objects, including faceplates designed for user roles (operator, maintenance).
View process and electrical control data in a common infrastructure.
Automatically assign the configuration of an original device (IP address assignment, firmware supervisor, device
configuration) to its replacement to reduce downtime.
Reduce startup delays by configuring your system prior to
installation, and also configuring controller and motor control
device I/O at the same time using Startup Wizards that step you
through the entire process.
Reduce errors and simplify programming by using a single software tool to configure all system devices.
Provide valuable operating data to the right person at the right time with access to predictive maintenance data from the control system.
10Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
SOLUTION AT A GLANCE
Integrated visualizationHMI, ERP,
MES, SMMS™IP CAMERA
USB CAMERAWEB
CONTENT
USERS & GROUPSAREAS
CON
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NFIG
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CON
SUM
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DEVICES
PANELVIEW™ PLUS PANELVIEW™ 5000
Provides secure configuration and content delivery.
Link content to the terminal by geolocation. Only allow access to the screens for the electrical panels from inside the electrical room.
Prevent operator errors by only allowing access to relevant content. Enhance
security by requiring that operators log in with
fingerprint ID or a retinal scan.
Accessible through cell phones and tables to
enhance employee mobility. OP
TIM
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ION
CON
DITI
ON M
ONIT
ORIN
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HMI
VIDE
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INST
RUM
ENTS
AS
SET
MA
NA
GEM
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Pull together content from multiple systems into a single operating environment. Connect one or more monitors to a single thin client and control them all with one
keyboard and mouse.
Divide each monitor screen and host content from various
sources. Create an operator station with a single 4K monitor
instead of multiple smaller monitors positioned next
to each other.
Use the multi-monitor function to create low-cost
video walls. An open solution allows you to connect to
multiple softwares.
11Solution architectures PG 2
Mine-wide process control systemPG 5
Flotation level controlPG 6
E & H process instrumentsPG 7
Process optimizationPG 8
Power and controlPG 9
Integrated visualizationPG 11
Publication MIN-SP008B-EN-P - November 2020
Copyright © 2020 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
AllenBradley, ControlLogix, expanding human possibility, FactoryTalk, FactoryTalk Analytics, FactoryTalk InnovationSuite, LogixAI, PANELVIEW PLUS, PANELVIEW 5000, PlantPAx. PowerFlex 7000, PowerFlex Low Voltage and Medium Voltage Drives, Rockwell Automation, ThinManager, and TotalFORCE are registered trademarks of Rockwell Automation, Inc.
All other trademarks and registered trademarks are property of their respective companies.
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