abb mining&mineral

7/28/2019 ABB Mining&Mineral

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ABB in Mining & Mineral Processing


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Costs of exploration and development in inaccessible areas.

Volatile market prices. Rising costs. Safety of workers.

Stringent environmental requirements. 100 % availability,

often in the harshest of climates. These are major challenges

facing mining and mineral processing companies today.

Team up with ABBWhether you are mining base metals, precious metals, coal,

or industrial minerals, the key is to manage operations and

information more productively. And availability of your elec-

trical equipment is crucial from the mine to your markets.

For more than 100 years we have been meeting these chal-

lenges head-on. ABB's experienced engineers help you

increase productivity and prots in mining and mineral pro-

cessing operations worldwide.

Underground Mining

ABB has a unique position as a sup-plier of complete mine hoists, includ-

ing both their electrical and mechanicalequipment. It has delivered more than600 hoists and undertaken the modern-ization of hundreds of existing plants

worldwide. Working closely with thecustomers, ABB has introduced a num-ber of technological breakthroughs formine hoisting systems, such as state-of-the-art drive and controlsystems, hydraulic disc brakes and controlled retardation, etc.

State-of-the-art drive and control systems

The latest technology, ACS 6000SD with DTC, Direct TorqueControl, for torque and speed control of AC motors is now wellproven for hoist applications. The first system to be installed isthe mine hoisting system at Pyhsalmi Mine in Finland. It hasby now been in commercial operation for close to four years

with the highest possible availability. This new drive systemoffers high efficiency, superior control performance, low volt-age drop in the supply network and low harmonic distortionas well as very low flicker. To date ABB has been awardedcontracts for totally 17 drive systems of this kind for friction anddouble-drum hoists for motor powers up to 8650 kW.

Complying with stringent safety and availability requirements of mine hoist applications, ABBs powerful, user-friendly controlsystem is based on IndustrialIT technology that includes controlof feeders, conveyors and measuring flasks at the loading levelas well as pushbutton control of multi-level man/material hoists.The AHM 110 Advant Hoist Monitor is an independent unit thatprovides protection against over-speed and over-winding.

Hydraulic disc brakes and controlled braking

Multi-caliper disc brakes are used for emergency stop and hold-ing at standstill. The hydraulic control unit is equipped withdual systems to meet the highest safety requirements. Con-trolled retardation maintains the set retardation rate indepen-dent of the actual payload and direction of movement.

Availability, Productivity


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and ProtsOpen Cast (Pit) Mining

Large open cast mining operationsthroughout the world have used control

and drive systems from ABB for decades. ABB electrifies and controls the full rangeof new and used mining equipment,including bucket-wheel and bucket-chainexcavators, spreaders, belt-conveyor sys-tems, belt wagons, stackers-reclaimers,crushers and shovel excavators. The high

reliablitiy and top performance of ABB equipment have beenproven to withstand the extreme conditions of open cast mining

with dust, severe vibrations, and temperatures ranging from -50 C to +50 C in over 1,000 large mining machines during the

past 50 years.

Ore Concentration

When it comes to driving grinding performance to higher lev-els, ABB offers a range of solutions. For example, the worldslargest gearless mill drive at that time (but now exceeded againby ABB) was put into operation in 2001. The ABB gearlessdrive for a 11,6 am diameter SAG mill with a power of 20,1MW and a base speed of 10 rpm was delivered to Antamina in Peru.For the concentrator plant, which is located at an altitude of 4300 metres, ABB also supplied gearless mill drive solutions(11,2 MW, 13 rpm) for the 3 ball mills as well as the power fac-tor and harmonic filter systems, the main power transformers,the plant-wide power distribution at the various voltage levelsand the plant-wide process control system.

Other examples of ABB plant- wide electrification and automa-tion as well as large gearless mill

drives installed in hydro-metal-lurgical plants can be found inmany large beneficiation plantsfor iron ore and concentrationplants for copper and other oresaround the world.

Processing and Rening

From agglomeration processes such as pelletizing and directreduction (DRI / HBI) of iron ore to the SX-EW, smelting and

refining processes of non-ferrous metals ABB provides a widerange of systems and solutions such as high power convert-ers, variable speed drives, power distribution, process control,instrumentation and process optimisation linked together by Industrial IT and combined with proven integration and projectmanagement expertise to ensure end-to-end plant connectivity and operational efficiency.

Process Optimization

Through its long involvement andexperience in the mineral processingindustry ABB has developed and suc-cessfully installed knowledge-basedsolutions. Creating value through inte-grated solutions for Industrial IT is pro-

vided by Optimize IT Expert Optimizerfor increased production through bet-ter average grind size, lower specificenergy cost, increased reagent efficiency and improved recov-ery. The Inform IT Knowledge Manager provides important plantoperational information such as metallurgical accounting, massbalancing, production and process management & KPIs, energy management and optimisation.

From copper and gold processing in Chile, Peru and North America, iron ore processing in Brazil and Venezu-ela to zinc processing in Australia, Canada and Peru, toname a few, ABB electrifies around the world.


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ABB in Mining & Mineral ProcFrom Mine to Market

Power CircuitBreakers, Relays,DisconnectSwitches

Ore Pocket WeighingSystems

Drive and ControlSystems for Open PitMining Equipment

Explosion Proof

Equipment

Gas InsulatedSwitchgear and

Industrial Substations

Financial Advisory Services

Electrication for

Hoist HaulageSystems

Electrical Equipment forRamp Haulage System

Underground Mining


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ssing

Look No Further Than ABB At ABB, our approach covers the complete value-added

chain, from your mine to the product you market. We excel

at merging equipment, skills, and services to develop a

complete, customized solution to strengthen your entire

operation, from mine to market, regardless of project size.

ABBs capabilities and global and local resources offer inte-

grated power, control, and information solutions. You specify

the requirements just once, and we take the responsibility for creating a solution that works smoothly and efciently.

Above all, it is a solution based on our solid, worldwide expe-

rience in the industry.

Mine Automationand Central Control

Material HandlingSystems

Project ManagementElectrical Systems Integration

Robot SupporteLaboratory Syst

Plant

AC/DC Drives, DrivesSystems, and Motors

Open Pit Mining

Stockpiles

Secundary Crushing

SAG Mill

SecundaCrushing

Screening

C

Ore Concentration

Ore Dressingand Preparation


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Drives Applications

You need more than electrical knowledge to interpret application

specications and select the correct drive system. ABB engineers

and manufactures motors and drive systems worldwide, from sub-

kilowatt applications to the megawatt ratings of gearless drives for

the largest SAG and ball mill applications. As a global leader, ABB

combines its extensive industry knowledge with its application

expertise to select the most economical drive solution for your

particular, often unique circumstances. We drive continuously for the highest availability, productivity and energy efciency your

operations can achieve.

Process Control and Automation

Mines and processing plants need integrated process control sys-

tems that can improve plant-wide efciency and productivity.

Our IndustrialIT solutions for process control, optimization and

management information provide easy access through a single

window to the process, production, quality and business informa-

tion from the most remote location to corporate headquarters.

Whether you are building a greeneld plant, extending or modern-

izing an existing plant, ABB provides tailored automation solutionsthat use real-time data enabling constant monitoring and analysis

of your process combined with improved asset availability.

Gearless Mill DriveInterofce and PlantData Exchange

Infrastructure: Grounding Lights, Protection,Lighting, Cabling, Communications Systems,Fire Protection

Integrated PlantwideDistributed Control

Reagents/ Conditioning

Ball Mill

Tailings Pond

To Water Treatment Plant

To Water Reservoir/Treatment

Flotation

Separation

To MarketProcess Water

cation

Primary Crushing

Cleaning

Secundary Crushing

Agglomeration Curing

Water

Ore StorageLeaching

Leached Soluti

Pump Station

Mineral Processing

Dewatering ThickenerFilters

To Tailings Pond

Motor ControlCenters


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Power Distribution and Conversation

When you need efcient and reliable power distribution in your

mining and mineral processing operations look to ABB. We offer

the broadest range of high, medium and low voltage equipment

for switching and distributing electrical power. Solutions are engi-

neered for safety, exibility and security to keep operations run-

ning day and night, including emergency power generation and

UPS, industrial sub-stations, power factor compensation and har-

monic ltering equipment, switchgear and transformers. ABB is aleading supplier of rectier systems required as a key element in

the electro-winning process as well as induction furnaces for your

melting and casting operations. ABB provides you with state-of-the-

art technology to exceed todays rigorous demands.

Services

Mining and processing thousands of tons of ore in a rugged

environment places substantial demands on well trained human

resources complemented by fast response service capabilities of

the major equipment suppliers. Life cycle support: ABB has an

extensive network of local service centers to support your facili-

ties. Our expert eld engineers are available day or night to diag-

nose, repair, upgrade, install or perform on-site maintenance for

ABB systems. The local centers can also provide training to your operating and maintenance staff in the local language. When it

comes to service, ABB focuses on helping your company succeed.

Emergency PowerGeneration and UPS

Transformers, Rectiers,

Switchgear, and PowerFactor Correction

Customer Service

Remote ControlSystems with SolarPower Supply

Radio CommunicationLinks

Electrolyte Filtration

Solvent ExtractionElectro-Winning

Product to Market

Concentrate to Smeltingand Rening Markets

Smelting and Casting

Process Instrumentation

Static VARCompensation andHarmonic Filters


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