Siemens Portfolio for Mining Industry · • Most powerful electric truck drive available ... •...

Siemens Portfolio for

Mining Industry

siemens.com/mining Likasi - 28th of November 2017

Page 2 PD SLN MN 28/11/2017 Page 2 PD SLN MN RG Copyright © Siemens AG. All Rights reserved.

Siemens portfolio for the Mining Industry

Products

Process

Engineering

Project management

Commissioning

Lifecycle services

Products

Vertical knowledge

Customer specific

solutions Know-How

http://www.automation.siemens.com/bilddb/picdetails.asp?objID=33953&lang=de&visMode=


Siemens Portfolio for the Mining Industry

Excavation Transportation Beneficiation Bulk Material

Handling

Electrification, Automation and Digitalization solutions for the entire mining process


Mining portfolio

Excavation Transportation and BMH Benefication Refining Agglomeration MES/Automation Energy distribution Service

Surface Crushing/Grinding For entire mining process Pri

ma

ry

pro

ce

ss


Mining portfolio

Excavation

Surface Pri

ma

ry

pro

ce

ss

Excavator Shovel Draglines Mine Winders


Mining portfolio

Transportation and BMH

Surface Pri

ma

ry

pro

ce

ss

Trucks Trolley Truck Conveyor Stacker/Reclaimer


Mining portfolio

Benefication

Crushing/Grinding/Electro winning Pri

ma

ry

pro

ce

ss

Gearless Mill Drives Conventional Mill Drives Pump Drives Electro winning


Mining portfolio

Excavation Benefication Transport

MES/Automation

For entire mining process Pri

ma

ry

pro

ce

ss


Mining portfolio

Instrumentation

For entire mining process Pri

ma

ry

pro

ce

ss

Leaching Coal Preparation

Electrowinning / Refining Smelting Transportation

In-Situ Leaching

Separation and Concentration

Material Handling (Underground)


Extraction


Shovels - Electrical Systems and Spare Parts

• Combination of 32 years of Siemens

AC shovel drive experience with

innovative IGBT/IGCT technology

• Future-oriented gearless technology

• No routine maintenance required

• Routine operation at over 98%

availability - benchmark reliability

• Maximised productivity

• Lower life-cycle operating costs


Draglines - Electrical Systems and Spare Parts

• No mechanical hoist and drag gears

• Top productivity and efficiency

• Minimized maintenance costs


Bucket Chain/Wheel Excavators - Electrical Systems

and Spare Parts

• Allows excavators to be loaded to their

performance limits

• Dependable high performance without

excessive wear and tear

• Fast, efficient fault clearance by means

of diagnostic systems


Transportation


Trucks - Electrical Systems and Spare Parts

• Most powerful electric truck drive

available (up to 6,000 hp)

• Combination of high torque, high

power, and ease of operation in an AC

drive system

• Increased payloads, shorter cycle

times, higher system reliability

• Reduction in operating costs far

beyond diesel / mechanical limits

• Even increased productivity and

energy savings with truck trolley

system

• Reliable partnerships with

manufacturers such as Caterpillar,

Komatsu, Belaz and NHL


Trolley Assist

• The inverters and traction motors are

sized for 6000 HP of retard power

• Trolley Assist utilizes this capability

• Speed on grade increases up to 95%

• Fuel and oil consumption are reduced

up to 80%

• Reduced engine wear in proportion to

lower fuel consumption

• Automatic connection to trolley line at

all speeds and line voltages

• Main Market Africa (http://www.youtube.com/watch?v=RJI4SguJ7Wk )

• Emerging Markets Australia, Chile

http://www.youtube.com/watch?v=RJI4SguJ7Wk


Advantages of Trolley System

Faster uphill haul shorter cycle time, higher productivity

Fuel savings, electrical energy less expensive

Longer engine life, lower maintenance costs

Additional costs for Trolley system minus savings result in a typical payback time

of 2-5 years !

More

tons / $

Page 18 PD SLN MN 28/11/2017 Page 18 PD SLN MN RG Copyright © Siemens AG. All Rights reserved. Slide 18

Belt conveyors


Conveyors

• High availability and reliability due to

robust drive components such as

motors and inverters.

• Efficient use of electric energy in every

phase of operation due to load-

dependent control of the belt speed

energy savings of up to 20%

• Increased productivity through

simultaneous starts and stops of all

conveyor and less downtime

• Low operating and energy costs

• Low maintenance costs


Conveyors

• High availability and reliability due to

robust drive components such as

motors and inverters.

• Efficient use of electric energy in every

phase of operation due to load-

dependent control of the belt speed

energy savings of up to 20%

• Increased productivity through

simultaneous starts and stops of all

conveyor and less downtime

• Low operating and energy costs

• Low maintenance costs


Gearless Drive Conveyors

• Higher plant availability by eliminating

electrical components, couplings,

bearings and gearboxes minimizing

risk of downtime

• Up to 4% higher energy efficiency

• Longer conveyors with fewer and

smaller drive stations

• Higher power at the pulley

• Reduced Maintenance Needs

• Fewer spare parts

• Reduction of noise level

Example data: Xstrata Antapaccay

Material: copper ore; Capacity: 5,263 tph

Conveyor length: 6,620 m; Belt Speed: 6.2 m/s

Belt width: 54”; Rating: ST 5,000; Drives: 1 x 250 kW, 2 x 3,800 kW

http://www.youtube.com/watch?v=N_RArJFQgXA




• The Mine winder is the centerpiece of

each underground mine

• Reduced travel time thanks to

intelligent travel control

• Maximum safety through the use of a

redundant, tested safety system

• Investment protection through the use

of standardized industry components

• Shorter cycle times, lower

maintenance costs

• Increased availability as a result of the

careful treatment of mechanical

components

Minewinder


Beneficiation


Crushers

• Robust drive components: AFD- Perfect Harmony

or Sinamics GM150

• Motor- Squirrel Cage Induction or WRIM (w/o

AFD) 1000-8000 kW

• Gearbox – Flender Planetary, Ratio 25 to 125:1

• LRT ~ 200% rated

• Commonly constant speed, however sometimes

variable speed to control size

• AFD useful in limiting starting current


Pumps

• Variable speed adjustment of pulp/slurry flow

• Pump shaft directly coupled to low speed SCIM

• Motor rated speed= Pump rated speed

• LV 300kW to 1000KW, MV 1000kw to 3000kW

• SIMINE Pump GD eliminates the reducer gear

and utilizes a AFD (Perfect Harmony) Drive +

Motor combination to achieve energy savings.


Conventional Mill Drives

• Siemens Integrated Drive System

The single supplier from the power

supply through the drive and motor to

the gearbox

• Optimized solution for any needs –

• WRIM fixed speed - also with Slip Energy

Recovery (SER) for higher flexibility with a

speed range from 80% - 120%,

• variable speed solutions for high operation

flexibility

• High or low speed solution to suit

customer’s preferences

• High operating efficiency thanks to

proven Frozen Charge Detection


Gearless Drive Mills

• Highest operating efficiency

• Controlled acceleration, deceleration

and stopping of mill

• Precise and fast positioning in inching

and creeping mode

• No downtimes due to lack of girth

gear/pinion maintenance

• Reduced downtimes due to frozen

charge shaker system

• Energy savings of up to 3%

• Higher availability of the grinding mill


Automation & MES


Automation & MES

• Minerals automation library based on

SIMATIC PCS 7. Further development

of the CEMAT DCS software for

cement that has been proven over 30

years of operation (more than 800

worldwide installations).

• Controlled startup and operation

• Optimized asset utilization and

management

• Increased operational efficiency

• Reduced and flexible engineering due

to modular library approach

• Less energy consumption and

environmental sustainability


Siemens Automation & MES

The glue for the entire mine process


MinAS: The Mining Automation Standard

SIMATIC PCS 7 System Components

The System Platform

SIMATIC PCS 7

• More than 50 years of

experience in

automation and controls

• Stable development –

now version 9.0

• Siemens - the second

largest DCS supplier in

the global DCS market

• Worldwide installed

base

CEMAT - MinAS

• Mining specific library -

+40 years

• High engineering

efficiency and quality

• Improved operations and

monitoring

• Advanced Process

Control

Engineering

System

• One (!) system to

engineering all DCS

components

• High engineering

efficiency

Operation System

• Intuitive Mining

Operations Philosophy

• Secure execution of the

process

especially in critical

situations

Automation

System

• High Performance

CPU’s

for the Process Industry

• Scalable from small

operations to very large

plants

• Industrial PC’s -

Servers

Process

Peripherals

• Industrial Remote IO’s

with small footprint

• Instrumentation for the

mining industry

• Robust Industrial

Communication


MinAS The Mining Automation Standard

The flexible network topology


MinAS / SIMATIC PCS 7

Scalability

Échelle d'évolution (1:1000), pour toutes les dimensions d'installation … aussi grand

que vous le souhaitez

Niveau d'équipement Site de production Sites interconnectés à un lieu

de production (par ex. commandés à distance)

Évolutif: Depuis le paquet de

démarrage (~100 I/O) ...

… au système multi-utilisateurs distribué

dans une architecture client/serveur

avec plus de 120 000 I/O

Convoyeur

Concasseur

Broyeur


MinAS – The Mining library

Main Features

Comprehensive library with specific features

and functions for the mining industry

• Operation Modes

• Group Control

• Global Object Browser

• Object List of Groups, Drives and Valves

• Information View for each Object

• Integrated MinAS Trend

• Integrated MinAS Maintenance

• Diagnosis View for each Object

• MinAS Alarm View and Filters

• Scalable Production Control



SIMATIC PCS 7/MinAS – The Mining library

Some References for Automation Solutions in Mining

VALE, Sechura Desert

in Piura

PHOSFATE BAYOVAR

2010 Phosphate Rock Mine

9 AS 5 ES 6 OS 120.000 I/O

HudBay,

Chumbivilcas

Constancia

2013 Copper Mine

15 AS 1 ES 5 OS 4.000 I/O

CAP MINERIA, Atacama

Region

Cerro Negro Norte

2012 Iron Ore Mine

9 AS(H) 2 ES 6 OS 4.450 I/O

PMC,

Ba-Phalaborwa area of

Limpopo

Migration Smelter and

Refinery Complex 54 AS 13 ES 5 OS 10.000 I/O 2011 Copper Mine

USIMINAS,

Minas Gerais

ITMs Friável e Nova

Oeste

2012 Iron Ore Mining Plant

9 AS 4 ES 6 OS 10.000 I/O

YAMANA Gold, Bahia

State

C1 Santa Luz Project

5 AS(H) 1 ES 3 OS 2.800 I/O

2011 Gold Mine


SIMATIC PCS 7/MinAS – The Mining library

Some References for Automation Solutions in Mining

Peñoles, Velardeña

Velardeña (Durango)

mining project

2 AS(H) 1 ES 4 OS 3.200 I/O

2012 Zinc Mining

LKAB, Kiruna

K-Terminal KUJ1365

Mining Project

22 AS(FH) 3 ES 8 OS 11.500 I/O

2011-17 Iron Ore Mining

RWE Power AG,

Garzweiler

Lignite strip mining plant

2006 Open pit coal Mine

95 AS (~7 ES) 35 OS 55.000 I/O


Reference

Safe underground operations with remote control

Customer Luossavaara-Kiirunavaara AB

(LKAB)

Solution

Customer PT Freeport Indonesia

Grasberg Underground Mining Project – Copper Mining

Solution Supply, engineering and commissioning of Process- and

train control system and Traffic Management system .

For increased safety, underground operations (driver-less

trains, crushers, loading points, unloading points) are

operated remote from the central control room at the

surface.

• Process Control System is Siemens SIMATIC PCS 7

• Interface (HMI) the Bombardier train safety &

management control to SIMATIC PCS 7

• Catenary and rectifier stations are delivered by Siemens

• All equipment is workshop tested and all applications are

simulated

• FAT (factory acceptance test) prior to delivery

• Time line – from conceptual to implementation: 3 years

*In cooperation with Midroc Sweden.

Customer

Benefits

• High availability, long lifecycle

• High level of redundancy and reliability

• Increased personnel safety


Heavy Duty Rectifier

AC/DC - Power for Electrowinning


• A heavy duty rectifier system provides

a DC voltage supply with very high DC

currents for industrial applications.

• Voltages from 100 to 1200 V DC

• Currents from 10 to 120 kA DC

• High DC Currents are used in the

industry for e.g.

• Electrolysis

• Smelters

• Furnaces

Heavy Duty Rectifier

AC / DC Power

Source: Aurubis AG

Source: Siemens AG


Production of

nonferrous metals in

electrolysis and smelters

Production in the

Chemical Industry

Chlorine

Sodium Chlorate

Flour

Hydrogen

Copper

Zinc

Nickel

Lead

Magnesium

Aluminium

Steel (ferrous)

Source: Aurubis AG

Source: ThyssenKrupp Uhde GmbH

Source: Norsk Hydro

Source: Asturiana de Zinc

Heavy Duty Rectifier for Electrowinning and

Electrolytic Refining


Power Solutions


• In mining, nothing works without power

• We offer complete solutions for power

supply and power quality.

• Power supply covering all voltage levels

and devices:

• high voltage switchgear

• medium voltage switchgear

• low voltage switchgear

• transformers,

• harmonic filters

• multi functional protection relays

(protection, control and display)

• e-houses

Power Solutions - Optimized supply and quality for

the mining industry

MV Switchgear

HV Switchgear

(GIS or air-insulated)


Your benefits include:

• Highest transparency through

monitoring of network and load data

• Low maintenance and investment costs

• Low electrical losses

• High availability and reliability

• Optimized power supply quality -

meeting utility requirements

• Highest personnel safety

• Reliable solutions based on state-of-

the-art technology and a worldwide

network of experts

Power Solutions - Optimized supply and quality for

the mining industry


Energy saving

Economic and ecological significance

• In General:

Electric drive systems represent 70 % of industrial power

consumption

• In Cement Plants:

Electric drive systems represent 90 % of industrial

power consumption

High potential for Energy saving in cement process

Low-loss drive

technology

n

Optimum

process

Power

management

Energy-saving

motors

High energy costs have direct impact on the operating costs. To reduce operating costs

means to produce in more environmentally friendly fashion and more economically.


Electrification

Optimized supply and quality for the cement industry

TIP offers more

Power supply covering all voltage

levels and devices:

• High voltage switchgear

• Medium voltage switchgear

• Low voltage switchgear

• Transformers

• Harmonic filters

• Multi functional protection

relays

(protection, control and display)

Our products and solutions

HV switchgears (GIS / AIS) MV switchgears (GIS / AIS)

LV distribution and MCC


Power generation solutions

Simple cycle

e.g. gas turbine generator

packages for supplying

power to industries and

residences

Combined cycle / Cogeneration

e.g. combined heat and power

(CHP) applications for utilities

and municipalities

Industrial Solutions

Power Generation Process Steam

Gas Turbine/

Generator/ Steam

Turbine / Condenser

Auxiliary Systems

Enclosures

Air Intake

Power Control Center

Stack optional

Tailored scopes and solutions to fit all project needs Full Turnkey

Power Plant

Package


Process Instrumentation

Simple cycle

e.g. gas turbine generator

packages for supplying

power to industries and

residences

Leaching Coal Preparation

Electrowinning / Refining Smelting Transportation

In-Situ Leaching

Separation and Concentration

Material Handling (Underground)



Product portfolio at a glance

Software

SITRANS

Library

SIMATIC PDM

Temperature

Transmitters

Sensors Rail Field Head

Flow

Electro-

Magnetic Ultrasonic Coriolis Vortex

Level

Radar Ultrasonic Level

Switches

Pressure

Absolute

Pressure

Differential

Pressure

Hydrostatic

Pressure

Positioners

Electro-

Pneumatic

positioners


Weighing and batching systems

Product portfolio at a glance

Weighing Electronics

Stand Alone Integrators PLC Based Weighing Modules

Load Cells and accessories

Single

Point

Bending

Beam

Shear

Beam

S-Type Compression Bending

Ring

Belt Weighing

Belt Scales Speed Sensors Accessories

Weighfeeders Solid Flowmeters



Collection of valuable process data

• Seamless integration in

automation

• Increased safety

• Environmental

responsibility

• Higher availability

of the instruments

• Reduced maintenance

• Reduced engineering

time

• Fast, reliable and correct

data and diagnostics from

the field at any time

• Better production

efficiency

• Improved energy

consumption

• State of the art

automation

Industry challenges Siemens instrumentation solutions

Vert

ical

inte

gra

tio

n t

hro

ug

h a

uto

mati

on

Waste fuel

inventory

Belt scale

Weightlifter

Wireless LAN

Kiln gas analysis

Instrumentation integrated in automation

Emission

Monitoring

Tyre weighing

Overfill protection

Air consumption

control

Water flow

monitoring

Wireless HART

Safety

• Process safety requirements

• People’s safety requirements

Sustainability

• Emissions legislations

• Water management

Production efficiency

• Increase production with less manpower

• Increase output with lower grade material

Energy efficiency

• Reduce fuel consumption

• Reduce electricity consumption

Wireless data communication

• Remote locations and moving equipment

• Data accessible from various locations

Alternative fuels

• Trend to recycle and recharge

• Maintain production efficiency

Customer benefits

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