Digitalization and innovative modular plant concepts give new opportunities for plant optimization
In concentrator plants - specifically in flotation - precise automation is crucial to achieve outstanding recovery rates. The automation solutions that are still in operation at mine sites around the globe show signification improvement potential when it comes to the control of process sections. External linkages and old components result in a lack of control accuracy and frequent downtimes of equipment due to failures or maintenance efforts recalibrating control loops. As the life cycle of these kind of plants is usually longer than 20 years, they require a step-by-step modernization program, especially for the control systems, so that the latest technology can be used to best effect.
Installing modern automation results in more stable processes, fewer interventions in process control and thus in increased yield in the flotation cells. New distributed control concepts not only allow more intelligence to be brought into the field, they also enable processes to be monitored by installing tools ‘on edge’. The presentation shows and discusses how new automation concepts can be implemented in an existing overall automation system. By upgrading the system, artificial intelligence (AI) tools for monitoring and improvement can be used too. The corresponding measured process data provides new process information. Anomalies in the process can be detected, automatically analyzed, and give a first indication of what might become a problem for plant operation in the near future.
Problems that have been detected can be fixed during the next scheduled shutdown and unplanned shutdowns due to failures can be avoided. This results in increased productivity. With use cases from the mining industry the presentation shows what can already be done now and how these tools can be used to implement predictive maintenance concepts and processes.
New digital field components can also be used for process control to save CAPEX and OPEX costs when considering the life cycle of a plant. In addition, with these automation technologies the CO2 footprint of pneumatic actuation can usually be reduced by more than 50%. The presentation discusses this topic based on use cases.
• Using digital technology to solve the usual contradiction between standardization and flexibility in engineering and operation
• Savings potential of CAPEX and OPEX costs during life cycle
• Reduction of CO2 emissions during operation and how the way to a carbon-neutral production can be supported.
All these solutions can be used for new projects as well as for the modernization of brownfield plants.
We will be pleased to discuss opportunities for plant, process and automation improvements with you, from the field level to cloud applications using the latest technology like AI on edge. And we look forward to your registration for our global webinar.
Presented by
Thomas Bertsch,
Global Industry Segment Manager Mining & Minerals Processing
Thomas is the Global Industry Segment Manager Mining, Minerals Processing and Heavy Industries at Festo SE & Co. KG. Starting with Festo in 1997 and based at Festo headquarters in Esslingen, Germany, Thomas has spent the last 15 years focused on product and business development within the Process Industry Segments, which includes Mining & Minerals Processing. Thomas has a Dipl. Eng. in Industrial Engineering from Albstadt-Sigmaringen University in Germany.
Dr. Eckhard Roos,
Head of Global Industry Segment and Key Account Management Process Industries, Vice President
Dr. Ing. Eckhard Roos studied electrical energy technology at the Technical University of Darmstadt and doctorate in this field. 1987 he joined the automation department of corporate engineering of Hoechst AG in Frankfurt and had the following responsibilities: Development of CAE systems for planning and engineering/design of automation systems for chemical and pharmaceutical plants. In 1995 he joined ABB Germany as Head of Engineering, from 1997 Head of the Business Unit Chemicals, Oil & Gas with responsibility for the process control business. Since mid-2006 he is Head of the Industry Segment Management Process Industries of Festo SE & Co KG in Esslingen, Germany.
He is active in several automation working groups within VDI (Association of German engineers) and ZVEI (Association of the German Electric and Electronic industry).
