The ASIA Miner - Reporting Important Issues to Mining Companies in the Asia Pacific Region
Issue link: https://asiaminer.epubxp.com/i/830355
Volume 14 • Issue 2 | 2017 | ASIA Miner | 11 Future of Coal The TLO is an integral part of the pit to port operation. Post upgrade, the TLO is now averaging 10,000 tonnes per train. profiles to meet coal height and bogie loading requirements. "There are substantial penalties involved if a train is not loaded cor- rectly with the right profile over the bogies. Overloading results in significant penalties but there is also an issue with under loading as each wagon loses capacity, which directly impacts on effi- ciency and profitability, but also entails a safety issue and risk of derailment. Reducing weight variations to optimise the amount of coal loaded per train is the ultimate goal in automating the TLO," explained Stephen Mount. Considering variables such as operator fatigue, time of day and environmental conditions presented challenges for MRA in developing the automated TLO system. To address this, MRA's solution was developed to use predictive modelling and ad- vanced filtering methods to compensate for aberrations in raw data and allow for environmental compensation through scan- ning methods and adaptive software. The Logix controller provides the platform for feedback con- trol and real time output of data through Ethernet/IP communi- cations. This use of smart technology with self-diagnostics and alarming provides an intelligent and intuitive system that removes the guesswork for operators. By automating the TLO, the oper- ator performs a supervisory role either from the TLO or a central control room during loading to monitor the system. Anglo American's Capcoal Control System coordinator Antho- ny Manousso said, "When you automate a process, you have to consider all variables in the design and commissioning phase. We did that and the way the system is running now the operators can sit in the control room and monitor the process. The opera- tor interface is easy to use so training requirements are minimal." Reduced downtime When it comes to a TLO, time is money and therefore any amount of time that the system is down has direct impact on profitability. One of the features of MRA's TLO system is that the outage time for installation is minimal. "It took less than a day's downtime to go from the existing system at German Creek to the new auto- mated TLO. The bulk of our commissioning is done remotely by accessing the PLC online to make any required changes, which saves significant costs with no need to go to site," said Peter McPherson. "Once the scanners are installed prior to the cutover we record live data from the site and undertake detailed simulation prior to installation to make sure it's working as per the specification. This reduces not only the commissioning time but also the need to delay trains post installation." Return on investment Having been in operation for approximately three years, German Creek has recorded real time results indicating a return on invest- ment of less than four months for the TLO automation system. Prior to the upgrade, the TLO was consistently achieving aver- age payloads in the order of 9100 to 9300 tonnes per train. Post upgrade, the subjected TLO is now averaging 10,000 tonnes. "With a monthly average increase of approximately 700 tonnes per train, based on 40 trains per month, this equates to signifi- cant efficiency returns," said Stephen Mount. Automating the TLO also provides significant benefits in terms of improved safety by reducing the risk of derailment from under loading, which can also have detrimental environmental effects resulting from spillage. In addition, automation removes opera- tors from potentially hazardous situations and fatigue issues can be avoided. "The coding that MRA developed within the ControlLogix PLC is extremely efficient and reliable. We are now using it for 98% of loading with only 2% being loaded manually as a result of external factors. This TLO system is an integral part of our pit to port operation - the end goal is to make sure our trains are fully loaded," explained Anthony Manousso. Rockwell Automation Australia and Rockwell Automation New Zealand are subsidiaries of Rockwell Automation, Inc - a leading global provider of industrial automation and information solutions that help manufacturers achieve a competitive advantage. The company brings together leading global brands in industrial auto- mation, including Allen-Bradley® controls & services and Rock- well Software® factory management software. Its broad product mix includes control logic systems, sensors, human-machine inter- faces, drive controllers, power devices, and software. Automating the TLO process delivers improved capacity, profitability and safety at Anglo American's German Creek mine.