Trends in Control and Power Technologies and Its Impact for Mineral Recovery Rates

TRENDS IN CONTROL AND
POWER TECHNOLOGIES AND
ITS IMPACT FOR MINERAL
RECOVERY RATES

Rolan Marrill, National Account Manager
Mining, Minerals and Metals
Schneider Electric
SME Annual Meeting and Exhibition 2013

Trends and its impacts

Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012

Mining Industry is facing unprecedented
challenges:
Asset Safety

People Lack of Skilled
Safety People

More Ore,
Control Systems
Process by
Growing
Larger Plants &
More Complex
Equipment
Mining Business

More Energy
Decline Of
Delivered
Mineral
by Larger
Grade and
/ Complex
Reserves
Systems

Cost Escalation
for
Regulations
New
Developments


People Safety Evolution
Control Room


Lock Out and Tag Out (LOTO)
Failure to Lock Out and Tag Out (LOTO) equipment power sources continues to result
in mine fatalities.

Figure 1. View down an else in an Electrical Figure 2. Arc Fault Event, created in
equipment room. (Open Source on Internet) Power Research Lab

Schneider Electric – - Industry Business – How to Manage Your Legacy Automation Equipment – 2012
Schneider Electric Presentation Title – SME 2013
Schneider Electric – TRENDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013

● Engineer the system for safety and reliability
● Studies completed to identify the hazards. (Reliability = Improved
safety)
● Training is critical and maintaining a staff of qualified people is a must.
.

Skilled
Skilled
People
People Personals
Personals
++ Safety
Safety
Training
Training

Reliability
Reliability Asset
Asset
Safety
Safety

Figure 3. Installation of new Circuit Breaker in
Existing 480 Volt Distribution Equipment.)


● Upgrade systems (or Retro Fit) latest and best protection systems for
your application.

Skilled
Skilled
People
People Personals
Personals
++ Safety
Safety
Training
Training

Reliability
Reliability Asset
Asset
Safety
Safety
Figure 4. Switchgear Virtual Main Arc Flash Mitigating
System (SVMS)


● Engineered solutions and products can be used to reduce
incident energies. No one solution nor product is a “fix-all” in
these complex electrical systems. What works in one system
will not provide any additional benefit or protection in another.

Skilled
Skilled
People
People Personals
Personals
++ Safety
Safety
Training
Training

Reliability
Reliability Asset
Asset
Safety
Safety
Figure 6.
Picture of Low Voltage Motor Control Center


Energy as the new process variable
Control Room Evolution


Energy and Mining
● Understanding benefits of metering at critical points
and control of energy uses from a top-down, high-
level understanding will aid in obtaining the most
efficiency out of the energy consumed.
● Energy Efficiency concerns have driven the
application of sophisticated power correction and
harmonic correction systems in the mine electrical
systems.
● Input from knowledgeable electrical engineers and
consultants will aid in making the best decisions for
overall Energy Efficiency.
Figure 7. View of operator using Power
Management Software



Figure 9. Modern Control Room
Figure 8. Control Room with Annunciation panels

● Industries no longer see
annunciator panels. Now the
standard is a bank of high
definition monitors spread
across the control console.
● Demand for more realistic
and detailed graphics
● Use of video cameras and
other technology allows
operators visual real-time Figure 10. iPad(R) with control application running
views in the facilities.

Control Room Evolution-Get Ready for change

Figure 10. iPad(R) with control application
running Figure 11. Head gear with graphic display
Open Source Internet
● More and more business management
professionals are moving their daily •These modernized control centers
business functions to devices such as and control rooms enable an
an iPad or a tablet. additional benefit that simulators
can and will be used to train the
new operators in a very realistic
setting.


The Information Revolution


Communications and Data are now
everywhere.
● Industries have more data
from more sources every
day and the need for
systems to help manage all
this information has never
been greater.
● There is a need to get more
out of these processing
plants than ever before.
● The mining boardroom
considers the process and
production improvements to
be gained as very desirable,
since the risk of production
loss or reduced production is
very unacceptable today.


How to manage and align all this data.

● Advanced software systems sometimes
called mine execution systems (MES)
are helping management and operational
teams reduced downtime, improve
overall throughputs, track inventory, and
manage energy.
● Occasionally, in mining operations the
dilemma is the excess of information.
● True pit-to-port or mine-to-finished
product delivery solutions enable
management to see production and
corresponding results in profit and loss.
● These systems enable all key operation
people to see the impacts of each
outage, slow down, or improvement in
production.
● MES systems also help identify costs by
To Quote Lee Freeman: area or action to give operations the tools
to better manage and maximize
“I now know more, then I understand…” profitability.


Network Security
and Growing Role
of IT


Network Security and Growing Role of
IT
● Devices need to be equipped
with some form of protection
● Control systems will have to
be able to identify and cross-
certify the authenticity of the
commands from mobile
devices
Figure 12. Picture of a Data Pod ● IT departments in mining
(Small Modular Data Center) sector are growing
● Much of the data that the
industry now manages is
digitalized and networked
● Process Control Experts
becoming IT experts


Conclusions
● Safety will remain a key issue and driver of
research and development of new electrical
equipment and solutions.
● Training in all aspects will continue to evolve
and adapt new technologies
● More energy will be used in processing low-
grade ores and in the future the demand for
technology will continue to be developed to
meet the needs of the mining community.


Conclusions
● More source points of information
will be required and collected.
● Demand for easy-to-read
dashboards and reports will
continue to rise.
● Rise of mobile applications for
control and monitoring
● More integration of process and
production into business tools

Figure 13. Control Room Dashboard


Conclusions
● Improvements will include but are not
limited to:
● Expert systems
● ERP
● MES
● LIMS
● PIMS
● Quality control
● Asset management
● Dispatch systems
● Mining planning Figure 6. View of operator using Power
● Mine scheduling Management Software
● Energy management
● These systems, when well integrated and
utilized can show the efficiencies to be
gained in the process, operations, and
energy consumption of mining plants


Thank You!

Schneider Electric – - Industry IN CONTROL AND Manage Your Legacy Automation ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013
Schneider Electric TRENDS Business – How to POWER TECHNOLOGIES AND Equipment – 2012

Trends in Control and Power Technologies and Its Impact for Mineral Recovery Rates

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