Engineering & Mining Journal

MAR 2019

Engineering and Mining Journal - Whether the market is copper, gold, nickel, iron ore, lead/zinc, PGM, diamonds or other commodities, E&MJ takes the lead in projecting trends, following development and reporting on the most efficient operating pr

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ENERGY EFFICIENCY MARCH 2019 • E&MJ 37 www.e-mj.com the most efficient design, build and opera- tion of any open-pit, underground, mineral processing or refining facility. ABB's scope of supply for this project includes its ABB Ability System 800xA digital automation system, as well as three gearless mill drive systems, and a high-pres- sure grinding roll to handle the increased amount of ore that will be processed in this expansion. The delivery also includes distri- bution transformers and substations, motor control centers, medium and low voltage drives, mineral processing specific applica- tions, and other automation and electrical equipment. Furthermore, ABB will provide project engineering, installation and com- missioning services, and ongoing remote monitoring and diagnostic services. ABB said its delivery will provide nu- merous operational and safety benefits for this project. It will monitor, control and manage all aspects of production, access critical information from system devices and provide detailed data analytics to determine process efficiency and identify opportunities for improvement. It will also monitor and manage energy distribution and consumption at this and other KAZ Minerals sites. Also available are power monitoring software solutions focused on specific equipment and systems. For example, ABB's Ability Smart Sensor package has been integrated into a Swiss pump man- ufacturer's product line, allowing users to monitor unit energy consumption and apply predictive maintenance to avoid un- scheduled downtime. In the conveyor market, Voith says its BeltGenius ERIC allows mine operators to see at a glance the efficiency of their conveyor belt systems at any time. The system continuously receives relevant performance data from the conveyor belt system, including belt speed, belt tension, effective motor power for all drive motors, and temperature. These parameters are then transmitted to a server at Voith. The server contains a digital twin of the system, in which all relevant information about the conveyor are stored, such as belt length, belt width, the diameter of the carrying rollers, drive pulleys, return pulleys, the configuration of the transfer stations, the topography, and the trough angles. Using this information, ERIC determines a nor- malized efficiency value referenced to the energy consumption for horizontal mate- rial transport, known as the Energy Per- formance Indicator (EnPI). This indicator allows the operator to quickly assess how efficiently the particular belt conveyor is currently operating. The data are visualized on the client's individualized user inter- face, in the form of an online dashboard. Voith says this normalization makes it possible for mine operators to easily compare all existing systems in terms of their energy performance. The digital twin compares the installed power to the ener- gy actually being used. This, according to Voith, allows the operator to identify pow- er reserves and put existing belt conveyor system capacity to optimum use without jeopardizing the safety of the system. Voith also offers the option of equip- ping individual belt segments with RFID chips. With this option, less-efficient belts and system sections are easier to identify through interaction between the digital twin and the RFID, according to the company.

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