Adroit Solutions in Metals, Mining & Minerals
Eliminate Down-time and Improve Quality
Adroit Solutions in Metals, Mining & Minerals Download
Adroit Solutions in Metals, Mining & Minerals
Enhancing Metals, Mining & Minerals with Adroit SCADA and Mitsubishi Electric Factory Automation Solutions
Introduction:
Adroit Technologies is a leading player in Research and Development, Production, Sales & Marketing, Training, and Support of software products for Automation, SCADA, MIS, and MES solutions. Alongside its technical services arm, Adroit Technologies Technical Services, the company excels in developing customized industrial IT, MIS, and MES solutions to cater to its diverse clientele. The Energy Sector, known for its complexity and scale, requires efficient monitoring and control of production plants. In this regard, Adroit SCADA, in combination with Mitsubishi Electric Factory Automation solutions, offers a comprehensive solution to tackle the challenges faced by this industry. This article delves into the capabilities and benefits of the Adroit SCADA and Mitsubishi Electric partnership, demonstrating how they ensure superior performance and safety for valuable energy assets.
The Mining, Metals & Cement Industries are vast and complex and the Adroit SCADA is ideally suited to assist in the efficient monitoring and control of even the most complicated production plant.
The rigid and quality-driven nature of this industry is ideally suited to the Adroit SCADA/HMI product. The time-tested and proven reliability of the product sees Adroit being used by large producers to safely run these valuable and strategic assets. The Adroit architecture and openness offer companies a unique capability of not only traditional SCADA/HMI functionality but the ability to integrate all aspects of their operations. By adopting a more holistic approach to Operations Management significant savings and operational efficiencies can be realised. In this sector, Adroit is uniquely placed to ensure a superior quality of supply in all aspects of the operations and management of these facilities.
Adroit Solutions in Mining, Metals & Cement Industries – Target areas:
- Diamond Mining
- Gold Mining
- Aluminium Production
- Phosphate Mining
- Coal Mining
Adroit Solutions in Metals, Mining & Minerals – Challenges :
- Energy Efficiency: The resource-intensive nature of mining and cement production processes requires efforts to optimize energy consumption and reduce carbon footprints.
- Traceability: Ensuring the traceability of materials and products throughout the mining and production processes is essential for quality control and compliance.
- Predictive Maintenance: The heavy machinery used in mining and cement production needs predictive maintenance strategies to minimize downtime and costly repairs.
- Remote Monitoring: Monitoring and controlling vast mining areas and remote cement plants present challenges in remote management and oversight.
- Reporting: Generating comprehensive and accurate reports is necessary for regulatory compliance, sustainability reporting, and decision-making.
Solutions:
- SCADA (Supervisory Control and Data Acquisition): Utilizing SCADA systems for centralized monitoring and control of critical processes in mining and cement production, improving efficiency and reducing energy waste.
- PLC (Programmable Logic Controller): Implementing PLCs for automation and precise control of various equipment and machinery involved in mining and cement production.
- HMI (Human-Machine Interface): Employing HMIs to provide an intuitive graphical interface for operators to interact with control systems and monitor processes efficiently.
- LVS (Low Voltage Switchgear): Using LVS for distributing electrical power and ensuring the safety of electrical equipment in challenging environments.
- High Power VSD (Variable Speed Drives): Utilizing high-power VSDs to control the speed of motors in mining and cement equipment, resulting in energy savings and better process control.
Conclusion:
By implementing these solutions, the metals, mining, and cement industries can address the challenges they face and optimize their operations. Energy efficiency measures will reduce operational costs and environmental impact, while traceability ensures the quality and accountability of the products. Predictive maintenance will enhance equipment reliability and productivity, and remote monitoring enables real-time oversight across vast operational areas. Reporting capabilities will help companies stay compliant and make data-driven decisions for improved performance.
Adroit and Mitsubishi Electric Factory Automation Solutions in Metals, Mining & Minerals
Saldanha Steel, South Africa
Saldanha Steel is a South African steel company which was originally formed as a partnership between Iscor Limited and the Industrial Development Corporation (IDC). Saldanha Steel is part of Mittal Steel South Africa which in turn is part of the global steel company Arcelor-Mittal. Saldanha Steel, an ultra-modern, instrument intense, 24/7 steel processing plant relies on the Adroit SCADA HMI to monitor operational pipeline consumption, environmental data and plant emissions.
Saldanha Steel is a compilation of four plants, each with its own consumptions and processing functions, namely the Iron making plant, the Steel making plant, the Caster and the Mill. In order to visualize the plant’s total operations and monitor expensive consumptions, Saldanha Steel installed a stand-alone Adroit SCADA HMI as its Central Monitoring System (CMS) with a server located at the Meltshop and an interface workstation located at the Central Services Monitoring Room.
Adroit Stand-Alone
– 2500 Scan Points and 12 Remote Client Connections
Modikwa Platinum Mine, South Africa
Modikwa Platinum Mine is an independently managed, 50:50 joint venture between ARM Mining Consortium Limited and Rustenburg Platinum Mines Limited. The mine is on the border of the Mpumalanga. Modikwa is a 200 kTPM concentrator controlled by three Siemens S7-400 “Hot-Standby” PLCs. State-of-the-art “Profibus”, “Industrial Ethernet” and ASI bus systems have been utilized extensively eliminating the need for any conventional I/O. The plant has a total of 580 drives all equipped with the Siemens Simocode.
The flotation plant has a total of 70 flotation cells that are each equipped with Level control and Airflow control loops.
The Adroit SCADA system is “Dual redundant” with automatic switchover in the event of a failure of any component.
Adroit Active Cluster
– 25 000 Scan Points and 5 Remote Client Connections
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Highveld Steel, South Africa
Highveld forms part of Evraz, one of the world’s largest vertically integrated steel and mining businesses, registered in Luxembourg. Evraz produced 16.3 million tons of crude steel in 2007, making the company one of the 15 largest steel producers in the world.
The site’s SCADA system consists of nine 984 PLCs of various brands. The plants are linked by a Modbus+ protocol network loop, via an SA-85 card driver to the Adroit system. All plant PLCs use input and output coils configured in Adroit which further map the operations addressing requirements.
The intranet network links all PCs with Ethernet addresses to monitor all network PCs.
The SCADA system is linked via its own van SCADA network, with 19 computers on
the network and 6 servers.
With the addition of the planned chemical plant, the network will consist of a total of
21 PCs and 8 servers.
Adroit Active Cluster
– 50 000 Scan Points and 40 Remote Client Connections
Debswana Damtshaa Mine, Botswana
Debswana is the world’s largest diamond producer by value. The company has operations at Jwaneng, Orapa, Letlhakane and Damtshaa. The main purpose of Debswana is to mine and recover gem and industrial diamonds. Although Debswana uses the most up-to-date technology to carry out its business, it is The technology, the people it employs and the skills they bring that make Debswana a successful operation.
The Damtshaa diamond mine is a diamond mine located in Botswana about 220 kilometres (140 miles) west of Francistown. Damtshaa is of open pit construction, located on top of four distinct kimberlite pipes of varying ore grades. The mine is forecast to produce about 5 million carats (1,000 kg) of diamond from 39 million tons of ore over the projected 31-year life of the mine. Adroit products are used for the control and monitoring of the ore crushers and ore delivery systems.
Adroit Active Cluster
– 50 000 Scan Points and 8 Remote Client Connections
Debswana Jwaneng Mine, Botswana
Jwaneng lies in south central Botswana,160km southwest of Gaborone. Jwaneng Mine contributes 60-70% of Debswana’s total earnings. The mine produces 9.3 million tons per year of ore and an additional 37 million tons per year of waste rock. The mine is located on three kimberlite pipes that converge near the surface, covering 520,000 square meters at ground level. In 2003, the mine produced 14.3 million carats (2860kg) of diamonds. The recoverable ore grade at the mine is about 1.25 carats per ton (250\mg/t).
This unique plant was a project that fully automated the sifting, sizing and sorting of diamonds. The idea is that no human operator would be involved in the entire process. The plant is complex and control and monitoring are critical to the recovery process.
Adroit Active Cluster
– 50 000 Scan Points and 20 Remote Client Connections
Debswana Orapa Mine, Botswana
The Orapa diamond mine is the world’s largest diamond mine. The mine is located in Orapa, a town in the Boteti Sub-District of Botswana about 240 kilometres (150 miles) west of the city of Francistown.
Adroit is used on the crushers, conveying, recovery operations, borehole and water recovery as well as the water treatment plants in the mine. The Orapa mining operations are mostly run by hot standby clustered Adroit servers with multiple client licensing. This is a completely automated recovery plant (CARP)that boasts more than one million real-time tags being read from more than- 25 Siemens S7 400 PLCs.
Adroit Active Cluster
– 50 000 Scan Points and 30 Remote Client Connections
Manganese Metal Company, South Africa
The Manganese Metal Company (MMC) is the single largest producer of pure electrolytic manganese metal in the world. The production facility is located in Nelspruit, in the Mpumalanga province of South Africa. Manganese Metal is manufactured using the process of electroplating and MMC has been using the Adroit SCADA since choosing it as their SCADA/HMI when they upgraded their legacy control system in 2000.
Operations at MMC are currently controlled via 12 SCADA machines each connected to a Programmable Logic Controller (PLC) varying from old Modicon 984’s to the latest Telemecanique Premium PLCs. The PLCs are all stand alone but the 12 SCADA machines are connected via an office network.
5 Sites with Adroit Stand-Alone
1500 Scan Points and 1 Remote Client Connection each
Mammatwan Manganese Mine, South Africa
Samancor Manganese is the world’s largest integrated producer of chrome and manganese units and is 60 per cent owned and operated by BHP Billiton. Adroit is used at a number of operations including Mammatwan and Wessels mine and the Tubatse Ferrochrome.
The town of Hotazel in the Northern Cape region of South Africa is home to Samancor’s Mammatwan open-quarry manganese ore mine and sinter plant, and Wessels underground manganese ore mine. Adroit is used to run the entire mining operations made up of seven areas. In addition, Alarm Management and Analysis and the Adroit SCADA Intelligence are used to drive operational excellence and the mines reporting requirements.
Adroit Active Cluster
– 50 000 Scan Points and 5 Remote Client Connections
Rare Earth Minerals Mine, South Africa
Namakwa Sands undertakes the mining and beneficiation of heavy minerals. The operation is located on the west coast of South Africa and operates facilities at three separate sites. The mine and the concentration plants are located at the Brand-se-Baai, 385km north of Cape Town. The mining concentrate is transported to the mineral separation plant by truck. The mineral separation plant is located at Koeknaap.
Here Ilmenite and Zircon are recovered before the products are transported to the smelter by rail. The smelter is based close to Saldanha Bay. Namakwa Sands operates two furnaces where Ilmenite is smelted to produce titanium slag and pig iron. The Namakwa Sands operation started in 1994 and is one of the largest mineral sand operations in the world.
Adroit Active Cluster
– 50 000 Scan Points and 10 Remote Client Connections
Harmony Gold Mine, South Africa
Harmony Gold (NYSE: HMY) is the third largest gold mining company in South Africa, the 12th largest in the world (2009) and the 5th largest gold producer in the world. Harmony and its subsidiaries conduct underground and surface gold mining and related activities, including exploration, processing, smelting and refining
Adroit is used in the monitoring and controlling of the liquid Cyanide addition into the CIL tanks and monitors the lime PH in slime as well as tonnage of the slime that is going back to the slime dams after gold extraction.
Adroit Stand-Alone
300 Scan Points and 4 Remote Client Connection
Batching Plant for Concrete, Ireland
Cement and concrete production plant of company Techmatik, City of Lubin
3x MAPS SCADA 1500 scan points
2x L-series PLC
2x Q-series PLC
Recipe module based on SQL Server DB and Microsoft Reporting Suite – included in the MAPS Product!
Anglo American, South Africa
Batching Plant for Cement & Concrete, Poland
Cement and concrete production plant of company Techmatik, City of Lubin
3x MAPS SCADA 1500 scan points
2x L-series PLC
2x Q-series PLC
Recipe module based on SQL Server DB and Microsoft Reporting Suite – included in the MAPS Product!
