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








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








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.








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








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


Integration with E+H process instruments








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








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








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.









Integrated visualizationHMI, ERP,

MES, SMMS™IP CAMERA

USB CAMERAWEB

CONTENT

USERS & GROUPSAREAS

CON

TEN

TCO

NFIG

URAT

ION

CON

SUM

ERS

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

IZAT

ION

CON

DITI

ON M

ONIT

ORIN

G

HMI

VIDE

O

INST

RUM

ENTS

AS

SET

MA

NA

GEM

ENT

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.








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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solution architectures for mineral processing plants

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