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Forging the Future: The Vital Role of Integrated Process and Power in Mining Operations

Integrated process and power technologies are revolutionizing mining operations, enhancing efficiency, reducing environmental impact, and fostering sustainability.

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A conveyor belt for processing coal ore.

The Asia Pacific region is a powerhouse of mining activity. Rich in natural resources, it is home to some of the world's largest reserves of minerals and metals. Countries like Australia, China, Indonesia, Mongolia and Japan are global leaders in the extraction of iron ore, coal, gold, and copper, underpinning the economic growth and industrialization sweeping across the region.

Amid this vibrant mining landscape, the integration of process and power technologies has emerged as a game-changer. Integrated process and power systems, combining advanced automation, intelligent power & motor control, and digital solutions are revolutionizing the mining sector to maximize asset performance and power management. These systems can help to enhance operational efficiency, reduce environmental impact, and drive sustainability in an industry traditionally known for its heavy energy consumption and ecological footprint.

As mining companies navigate the dual challenges of meeting increasing demand and adhering to stringent environmental regulations, the convergence of process and power technologies offers a pathway to a more sustainable and efficient future.

 

Why mining requires integrated systems for enhanced production

Mining is getting more complex as companies are forced to dig deeper and go further to access better ore grades. Mining companies continue to be challenged with identifying process efficiencies, improving equipment reliability, effectively using water and energy, and keeping people safe. Controlling these variables is crucial to maximize production in a sustainable way, while remaining profitable.

By leveraging advanced process solutions, mining operations can achieve significant improvements in performance, cost efficiency, and sustainability. Tested and validated architectures and functionalities for mining operations can help maximize performance of equipment and throughput, improving overall productivity in the production processes.

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Integrating process and power for efficient mining

Process management and power management are recognized as different functions, traditionally managed by different teams or divisions in an organization. To address current workforce challenges and respond to rapidly shifting market demands, companies are increasingly choosing to connect the two functions for more efficient operations.

To help connect teams and integrate platforms, Rockwell Automation offers a full suite of integrated process and power solutions, including intuitive data intelligence collation and analysis, control visualization platform and secure infrastructure.
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The integrated process and power systems take advantage of a single automation platform that allows cross-function visibility and communication, leading to lower costs and more efficiency for system management compared to standalone offerings. Those legacy siloed systems can be migrated into integrated systems which are easy-to-use, data-informed, secure by design, and sustainable and help mitigate risks in operations.

From conveyers, compressed air solutions, and mineral processing to stacker reclaimers, mobile vehicle data collection and compressor optimization – integrating process and power control solutions delivers significant operational, cost, and time efficiencies through digital technology and unified system architecture.

By harmonizing these applications, mining operations can achieve greater levels of productivity, reduce environmental impact, and unlock new opportunities for long-term growth.

 

Mining applications benefit from integrated systems

The latest PlantPAx® distributed control system (DCS) reduces automation infrastructure, delivers improved diagnostics and analytics and helps to ensure consistent process delivery by introducing controllers built specifically for process. It also helps users working in an evolving landscape of threats by adopting the industry’s latest cybersecurity standards.

By aligning energy consumption with operational demands, mining operations can achieve significant cost savings and minimize their environmental footprint, supporting a more sustainable and profitable industry.

A recent example is the Resolution Copper Project, a joint venture between Rio Tinto and BHP, that is implementing advanced control systems and energy-efficient technologies to improve safety, reduce environmental impact, and enhance operational efficiency at its underground copper mine, 60 miles east of Phoenix, Arizona, in the U.S. Key upgrades include using PowerFlex® variable frequency drives (VFD) and the PlantPAx DCS, leading to a 5% increase in system efficiency, a 10% decrease in utility costs, and annual savings of $1 million. The project aims to support the growing demand for copper, especially for electric vehicles.

 

Supporting mining productivity and innovation

In the rapidly evolving mining industry, the adoption of advanced technologies is crucial for maintaining a competitive edge and operational excellence. At Rio Tinto’s Amrun bauxite mine in Australia, Rockwell Automation’s integrated solutions exemplify this trend, supporting mining productivity. The use of PlantPAx for plant-wide control and FactoryTalk® software for real-time data access improved operational efficiency and safety. The integration of Allen‑Bradley® controllers and mobility tablets facilitated seamless control and data sharing, contributing to the project being completed ahead of schedule and under budget. This approach underscores the benefits of advanced automation in enhancing mining operations.

Mining and mineral processing companies continually strive to adopt cutting-edge technologies to optimize their operations. Multicom Resources, an Australian company focused on the development and production of high-purity critical minerals, recently selected PlantPAx DCS for its new plant to achieve integrated control, scalability, and flexibility. PlantPAx offers enhanced reliability, uptime, and user-friendly interfaces. Additionally, Multicom integrated PowerFlex 527 drives, ControlLogix® control systems, and FactoryTalk View SCADA system to streamline operations.

These examples illustrate the transformative impact of integrated technologies in mining. As the industry continues to evolve, the adoption of integrated technologies will be crucial in maintaining a competitive edge and ensuring long-term sustainability.

Explore more on how integrated process and power solutions can take your mining operations to the next level.   

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Published September 2, 2024

Topics: Process Solutions Mining Distributed Control Systems

Ana Mello
Ana Mello
Director, Global Mining and Metals, Rockwell Automation
With a career spanning over 30 years, she has strong industry and technology experiences, and focuses on helping mining and metals customers to unleash value from their operations in a safe, sustainable and secure way.
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