The Asia Miner

JAN-FEB 2017

The ASIA Miner - Reporting Important Issues to Mining Companies in the Asia Pacific Region

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VDMA 67 2017 • VDMA MINING SUPPLEMENT integrating the pipe conveyor into the existing network," Wolf said. The pipe conveyor is the connection between individual belt conveyors from various manufacturers." The concentrate is received by a 43-m feeding conveyor that transfers it to the pipe conveyor at a height of 6 m. A dedusting unit ensures that no material is emitted during this process. At the end of the route, the conveying system runs along the seaside in the naval port of Callao to the transfer tower. Here, the belt opens automatically and transfers the material to another belt convey- or that conveys the ore to the ship-loading system. "This modern system, in operation now for more than 17 months, has increased concentrate loading times by 500% and reduced the ship's waiting time until loading by more than 80%," Sam said. "These advantages passed savings on to the exporters and has improved the competitiveness of the Peru's mining sector." Transportadora Callao is now able to handle ships for bulk products of up to 60,000 DWT without obstructing the work in the other terminals of the Port of Cal- lao. Automation & Digitalization A pioneering technology leader for open-pit mining and bulk material handling systems, ABB Germany through its Center of Excellence in Cottbus offers decades of expertise in electrification and auto- mation of the entire mining chain, from pit to port. The ABB team provides integrated products, services and solutions to help mining customers optimize the value chain. A great example of this expertise is successful, long-term part- nership with Joy Global, a leading mining equipment supplier. During the last 10 years, ABB Germany has equipped 75 electric shovels with AC multidrive lineups, which are specifically developed for the most adverse conditions in open-pit mining. Daily, these shovels encounter high shock and vibration loads as they crowd and load rock from the face in some of the most challenging environmental conditions from the top of the Andes to the Arizona desert. ABB's proven ACS800 low-voltage drive systems are specifically designed and modified for the requirements of loading equipment. ABB is also participating in the electrification and automation of a 13-km-long conveyor system at the historic Chuquicamata copper mine. Once the project is completed, the conveyor system will be one of the world's largest and most complex systems and will deliver cop- per ore from the new underground mine directly to the concentrator. Chuqui is one of the largest open-pit copper mines and the sec- ond deepest open-pit mine, located in the Atacama Desert in northern Chile. The mine has been operating since 1910 and today it is operat- ed by Corporación Nacional del Cobre (Codelco) — Chile's national copper mining company and the leading copper producer. To cover both steep gradients and long distances, the conveyor flights will be powered up to 20 MW and 55 MW in total. In the final stage, the system will transport more than 11,000 tons per hour of material, the same freight as approximately 158 railcars per hour. ABB's delivered a complete power and automation solution, which includes gearless drives, motors, instrumentation and power supply products. The equipment will be custom-engineered to on-site requirements to optimally power, control, measure and actuate the conveyor system. The solution will fully integrate the belt's power and automation through ABB's flagship 800xA control system, combined with a Mining Conveyor Control Program (MCCP) to ensure optimum power quality and control across the entire system. A key part of ABB's delivery is the gearless conveyor drive sys- tem. This is a state-of-the-art solution to meet the extremely high load requirements and the necessary power availability, which would not have been achievable with a conventional drive solution. This gear- less conveyor drive system eliminates the gearbox from the motor, thus significantly reducing the number of main wear parts, resulting in less maintenance needed and ensuring a longer lifespan of the solu- tion. Other advantages are the considerable reduction in the drive system's footprint and the amount of instrumentation required. Less parts increases the reliability and efficiency of the overall conveyor system by several percentage points. Stockyard Management System Demonstrating the trend toward increasing digitalization, ABB of- fers a fully automated terminal management system or the stock- yard management system (SYMS). The first SYMS has been running at an iron ore distribution hub in Malaysia for two years now and the results have shown that it performs better than manual operations. The Teluk Rubiah Maritime Terminal is Vale's first fully auto- matic operating port, which uses its ERP System (GPV Portos) to create work orders for the port and yard operations, delegate them as jobs for material movement to the control system, and execute them by unmanned operating yard machines. The SYMS receives production data from Vale's Production Information Man- agement System (PIMS) and distributes it to the Process Con- trol System (PCS) to control the machinery. The scope of supply also included the design, engineering, delivery, installation, test- ing and commissioning of ABB's 800xA PCS to manage all plant equipment at the terminal, including all ship unloaders, conveyor belts, stackers and reclaimers. The unmanned yard machines are assisted by 3-D pile scanners and a GPS positioning system to ensure the highest level of accuracy and precision in order to achieve highest productivity. Before any material movement starts, all planned activities are validated by the SYMS for the correctness of the selected materi- al quality, sufficient space at the assigned destination to stack, or if enough reclaimable material is available to fulfill the job. In case of a valid status, the import, export and blending jobs are executed by the unmanned operating yard machines, which are fully automated. The movement of the material is monitored by a material tracking fea- ABB engineered the gearless drives, motors, instrumentation and power supply for the 13-km overland conveyor at Chuquicamata.

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