giuseppe di marco, abb: automation technologies - key for integrated mine to port solutions
TRANSCRIPT
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Automation technologiesKey to integrated mine to port operations
Guiseppe di Marco, President ABB in Mining, 6th Americas Iron Ore Conference, Rio de Janeiro, 12 Nov 2013
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© ABB GroupNovember 11, 2013 | Slide 2
A global leader in power and automation technologiesLeading market positions in main businesses
§ 145,000 employees in about 100countries
§ $39 billion in revenue (2012)
§ Formed in 1988 merger of Swiss andSwedish engineering companies
§ Predecessors founded in 1883 and1891
§ Publicly owned company with headoffice in Switzerland
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How ABB is organizedFive global divisions
© ABB GroupNovember 11, 2013 | Slide 3
PowerProducts
PowerSystems
DiscreteAutomationand Motion
ProcessAutomation
$10.7 billion36,000
employees
$7.9 billion20,000
employees
$9.4 billion29,000
employees
$8.2 billion27,000
employees(2012 revenues)
Low VoltageProducts
$6.6 billion31,000
employees
§ Electricals, automation, controlsand instrumentation for powergeneration and industrialprocesses
§ Power transmission
§ Distribution solutions
§ Low-voltage products
§ Motors and drives
§ Intelligent building systems
§ Robots and robot systems
§ Services to improve customersproductivity and reliability
§ ABB’s portfolio covers:
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© ABB GroupNovember 11, 2013 | Slide 4
Power and automation are all around usYou will find ABB technology…
crossing oceans and on the sea bed,
orbiting the earth and working beneath it,
on the trains we ride and in the facilitiesthat process our water,
in the fields that grow our crops andpacking the food we eat,
in the plants that generate our power andin our homes, offices and factories
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© ABB GroupNovember 11, 2013 | Slide 5
Ground-breaking and nation-building projectsPushing the boundaries of technology
Longest undergroundpower link
Longest and highestcapacity power link
Longest underwaterpower link
Largest gearless milldrive (for crushing ore)
Largest SVCinstallation
Most remote offshorewind farm linked to grid
First platform connectedto mainland grid
Europe’s largestthermal solarpower plant
First commercialwave power plant
First 600 kVpower link
Longest conveyor belt
Substation in world’stallest building
Power and automationof largest chemicalcellulose plant
Automation of largestalumina plant
Largest battery
Mine hoist forlargest potash mine
Largest reverse-osmosisdesalination plant
Largest SCADAnetwork
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© ABB GroupNovember 11, 2013 | Slide 6
Innovation is key to ABB’s competitive advantageLeadership built on consistent R&D investment
§ More than $1.4 billion invested annually in R&D§ 8,000 scientists and engineers§ Collaboration with 70 universities
§ MIT (US), Tsinghua (China), KTH Royal Institute ofTechnology (Sweden), Indian Institute of Technology (NewDelhi), ETH (Switzerland), Karlsruhe (Germany), AGHUniversity of Science and Technology (Poland)
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© ABB GroupNovember 11, 2013 | Ver. 1.1 Slide 7
Content
§ Introduction
§ ABB’s system approach - iron ore value chain
§ ABB Ventyx solution suite
§ Integration of information und operation technology
§ Conclusions
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IntroductionIron ore value chain
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© ABB GroupNovember 11, 2013 | Slide 9
ABB in miningKey facts
§ Offers comprehensive market-leading packages of ABB competencies,products and services for the complete production chain in mining andmineral processing industries
§ Combines global and local ABB competencies and resources to ensureoptimum service
§ About 3000 employees in 35 operating countries
§ > 60 complete plant electrification systems
§ > 120 gearless mill drive systems
§ > 300 belt conveyor solutions
§ > 600 mine hoist systems
§ > Automation for all the above
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The top challenges for global mining companies
© ABB GroupNovember 11, 2013 | Slide 10
Source: 2012Mining ExecutiveInsights Ventyxsurvey
Iron ore market hasbecome more volatileand short-term oriented
Reserves in remote areaswith a lack of infrastructureand political andenvironmental risksrequest rising CAPEX
Labour is more costly,energy costs are going upand volatile prices putpressure on margins andcash flow
The bottom line: How to continue to deliver high returns to shareholders
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© ABB GroupNovember 11, 2013 | Slide 11
Iron ore value chainFrom mine to market
Exploration,assessment
Planning,scheduling
Drill and blast Load andhaul
Processing
Shiploading
Stockyardload out
Railtransportation
Trainunloading
Stockyardblending
Achieve overall optimization of quantity and quality of suppliedmaterial, eliminate suboptimized islands
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Integrated Automation
§ Should provide all data required to manage the valuechain at all times along the whole production process
§ Should supply a consequential sequential effect analysison the entire process when one of the items within thatprocess defaults or gets changed
§ should permit immediate remedial actions to maintain therequired level of productivity and plant availability at alltimes.
§ Should promote collaboration along the whole ProductionProcess
§ Should permit Remote Operations favouring the un-manning (less people underground) and un-trucking(truckless) of Mines
© ABB GroupNovember 11, 2013 | Slide 12
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ABB system approachIron ore value chain
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© ABB GroupNovember 11, 2013 | Slide 14
Iron ore processing portfolio (1 of 2)ABB integrates solutions …
Beneficiation TransportationMining
Electrification and automation withSpecial mining drive solutionsGearless conveyor drivesDouble drum & friction hoistsIncl. brake systems & shaftsElectric UGM trucks, ventilation on demandPower generation, conversion& distribution
Integrated electrification, automation, control, instrumentation, drives & CPM solutions
Gearless mill drives (GMD)Ring-geared mill drives (RMD)High pressure grinding rolls (HPGR)applications – variable-speed drivePlant infrastructure & optimization
Services
Rolling stock & rail networksConveyor systemsLoading and unloading facilitiesStockyard managementCollaborative production management
Flotation / Separation
Screening
Ball mill
SAG mill
Railway systems
Slurry pipeline
Belt conveyor systemsCrushing
Mine hoists
Stockyard systems
Belt conveyors
Shovels
Fleet management
Inpit crushing
Stockyard systemsStockyard mgt system
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© ABB GroupNovember 11, 2013 | Slide 15
Iron ore processing portfolio (2 of 2)… to optimize productivity and efficiency
Terminal Melt shopPelletizing
Electrification / automationVariable speed drivesPower distributionProcess control &optimizationInstrumentationCollaborative productionmanagement
Integrated Electrification, Automation, Instrumentation & Drive Solutions
Conveyor systemsUnmanned operation of S/RStockpile managementQuality managementLogistics and sales management
Compressor drivesPower distributionEx protection equipmentProcess, safety controlInstrumentation, valvesCollaborative productionmanagement
Balling, induration
Grinding
Dewatering, filtering
Blast furnace
Electric arc furnaceTrain loading/unloading
Blending
Ship loader / unloader
DRI
Gas supply
Direct reduction
Hot briquetting
Furnace transformersStatic Var compensationPower distributionHV/MV substationsRectiformersDC/AC furnace electrificationMetalurgical steerers & breaks
ServicesIntegrated electrification, automation, control, instrumentation, drives & CPM solutions
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ABB road map - strategyHollistic view to information
Drill rigs Truck/fleetmanagement Crusher Benefication Pelletizing Stockyard Terminal
Control system Control system Control system Control system Control system Control system
Shovel
Control system
Electrical powerdistribution
Control system
One operation
”Set points” Real time data
Production Work Material People FinanceAssetsDesign
Production plan Asset availability Real time report Status on-line
Control, monitor in real time
Optimize based on plan and demand
Demand
Control system
© ABB GroupNovember 11, 2013 | Slide 16
Enabling collaboration and integrated decision making
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© ABB GroupNovember 11, 2013 | Slide 17
ABB portfolioExtended automationSystem 800xA
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Extended Automation System 800xAIntegration: One common automation platform
Benefits include§ Efficient engineering§ Organization of information§ Shared data§ Data that comes from various sources can be accessed
by multiple applications without separate interfaces!
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Control room
Control system
Control
Process
Protection &control IEDs
Promoting collaborationIntegration of process and power automation
Controller
Plant network
Controller
Profibus/Profinet
Substation automation
Process control server
IEC 61850
Process and power workplaces
Instruments
LV switchgear,drives, motorstarters
Process electrificationProcess instrumentation
Plant-wide sequence ofevents for better rootcause analysis
Same operations interfaceand engineering for sharedinformation and knowledge
Centralized historianand data archiving
CentralizedHistorian andData Archiving
Common, integratedasset managementstrategy
Electrical integrationbased on open standardssuch as IEC 61850,Profinet/Profibus…
Common systemtherefore reduced spareparts, training etc…
Standardized procedures,settings, control logic and
libraries
Standardized procedures,settings, control logic andlibraries
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© ABB GroupNovember 11, 2013 | Slide 20
Integration of automation and electrical devicesOne system approach
800xA based integrated sub systemsMain process and power control
Drive systems forgrinding
Automatic stockpileloading, unloadingtransport
ECS, ISA-95, OPC…
System servers
Extended operatorworkplace
WirelesscommunicationHigh integrity control
safety shutdownfire and gasAC800 M
process controller
Operation, engineering& Ventyx maintenance
Processoptimization
Ventyx productionmanagement
HeadquarterERP and business systems
Firewallrouter
Sub system controllerAC800 M
Corporate network
Automation system networkMobile / remote operation
engineering and maintenance
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© ABB GroupNovember 11, 2013 | Slide 21
ABB Ventyx solution suiteMining
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ABB - Ventyx solution suite
800xA - Process Control
Geological, mine plan,mine operations Ore & metal processing Product handling
& transport Shipping & sales
MineScape – Geologicalmodeling, mine planning,mine operations
CCLAS – Production quality and laboratory management
Ventyx Production Accounting – Mass balance & reporting
MineMarket – Product logistics and sales
Ellipse - Asset and work management
© ABB GroupNovember 11, 2013 | Slide 22
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MineScape: geologic modelingCreating a 3D map of the ore body
© ABB GroupNovember 11, 2013 | Slide 23
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MineScape: mine plan and scheduleDecisions support for optimal mine operations
© ABB GroupNovember 11, 2013 | Slide 24
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Ventyx Production AccountingConsolidate information: one single auditable version of the truth
Financial management system (e.g. ERP)
Mass, KPIs, metal content, inventories
Wet tons, volume, assay, mass, moisture, density, transaction, shift, day, week, monthWet tons, volume, assay, mass, moisture, density, transaction, shift, day, week, month
Metal accounting business processMetal accounting business process
Acquire Validate Authorize Calculate Report Publish Analyse Audit
© ABB GroupNovember 11, 2013 | Slide 25
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MineMarket: inventory managementKnow where and which material you have in the value chain
© ABB GroupNovember 11, 2013 | Slide 26
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MineMarket: ship loading and unloadingEnsure optimal ship loading according to market demandand enterprise capacity
© ABB GroupNovember 11, 2013 | Slide 27
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MineMarket: sales and marketingAutomatically generate correct invoices and certificates
© ABB GroupNovember 11, 2013 | Slide 28
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MineMarketVisualize logistics through the value chain
© ABB GroupNovember 11, 2013 | Slide 29
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© ABB GroupNovember 11, 2013 | Slide 30
ABB and Ventyx joint valueIT/OT case studies
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Grinding optimizationVariable-speed drives and advanced process control
Value proposition§ Variable-speed mill drives enable real
time mill speed optimization for highergrinding efficiency
Technology§ Combine variable-speed drive and
advanced process control to increasegrinding process performance
§ Mill fill “indicators” as key measurement
Benefits§ More production§ Higher energy efficiency§ Longer liner lifetime
© ABB GroupNovember 11, 2013 | Slide 31
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Use case Advanced Process Control in grindingInventory management & APC for optimal ore grinding
© ABB GroupNovember 11, 2013 | Slide 32
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Concentrator operationsLeveraging IT/OT convergence
The old way
§ Production, equipmentand other controlsystems not integrated
§ No information onrelative product pricing
§ No information on feedmaterial
§ Plant set points static
Value propositionIncrease plant recoveryand optimize product mixbased on current pricingand ore feed propertiesthrough leveraging APCacross processes andbusiness systems
(OT)Advanced processcontrol (APC)manages blending,grinding, flotation inreal-time
(IT)Geological model andreal-time materialtracking providesshort term feedcharacteristicschedule to APC
(OT)Advanced processcontrol (APC) usesthe information toincrease performanceand quality in real-time
(IT)Sales systemperiodically providesrelative pricingupdates to APC
(OT)APC refines controlset points tomaximize recoveryand energy efficiencyfor current feedmaterial and productpricing
(OT)Online analyzers andblending algorithmsreconcile actual feedwith qualityspecifications for betterpredictability
© ABB GroupNovember 11, 2013 | Slide 33
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Example: Stockyard managementManless operation, blending and material tracking
Value proposition§ Fully automatic stacking/reclaiming§ Material tracking and blending with
3D online visualization§ Task scheduling
Technology§ Laser scanner and GPS based
control (BulkExpertTM)§ Microsoft technology for visualisation
Benefits§ Less personnel§ Higher efficiency and throughput§ Lower wear and maintenance efforts
© ABB GroupNovember 11, 2013 | Slide 34
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Stockyard operationsLeveraging IT/OT convergence
The old way
§ Production, equipmentand other controlsystems not integrated
§ No exact information onmaterial distribution byquality and location
§ No synchronizationbetween train and shiplogistics
§ stockyard set pointsstatic
Value proposition
Increase stockyardthroughput with optimizedproduct mix based oncontract demands andmine output
(IT)3D modelling with realtime reconcilations by3D –laserscanners
(OT)Task scheduling tosynchronize train andship logistics
(IT)Sales systemperiodically providescontracting updatesto stockyardManagement
(OT)Stockyardmanagement refinescontrol set points forblending algorithmand routing pathselection
(OT)Online analyzerintegration andmaterial trackingproviding real-timedata
© ABB GroupNovember 11, 2013 | Slide 35
(OT/IT)ore blending torequested qualitybased on qualitymanagement and pilevisualisation
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© ABB GroupNovember 11, 2013 | Slide 36
Integration of Ventyx Ellipse in 800xA workplaceMaintenance information available in real time
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© ABB GroupNovember 11, 2013 | Slide 37
Integration of Ventyx Ellipse in 800xA workplaceMaintenance information available in real time
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© ABB GroupNovember 11, 2013 | Slide 38
Conclusions
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ABB’s integrated mine operating modelIT and OT enable collaboration and optimization
Monitor & control
Collaborate
© ABB GroupNovember 11, 2013 | Slide 39
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ABB TechnologiesMine enterprise management from mine to port
© ABB GroupNovember 11, 2013 | Slide 40
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