Mining & Metal

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Why is end-to-end optimization critical for sustainable mining? Naohisa Endo, Vice President of Yokogawa, shares insights in Mining.com

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BROCHURE
Smart Mining: The Future of Mining Plants Evolving Through Digital Technology

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English vesion | Spanish version

Worker and Plant Safety

• Introduction of Automation Technology
• Cyber Security Measures

Productivity Improvement

• Improving Efficiency Through Data Utilization
• Integration of IoT, AI, and Digital Twin

Optimal Plant Operation

• Strengthen Reliability with Smart Maintenanc
• Minimizing Downtime

Fieldwork Support

Enable safe operations by real-time sharing and digitizing video and audio

On-Site Challenges

• Takes time to get to the problem site
• Insufficient support leads to equipment failure and worker injury

Solutions

• Check the on-site situation utilizing clear video and voice calls from remote locations
• Write instructions from remote locations on documents and images displayed on mobile devices in real time
• Record the work details along with video, and share the information and create a manual at a later date

Benefits

• If any problems arise, the on-site situation can be shared early, and support can be provided to the site from remote locations
• Reducing the on-site work time and system recoverytime

Minimization of Cyber Attack Risk

Ensure appropriate security management for the customers' situations and effectively protect the plant from cyber attacks

On-Site Challenges

• No measures in place for dealing with security incidents
• Not sure where to start with security measures

Solutions

• Realization of end-to-end proposal and implementation of security measures, operation monitoring, and incident response based on IEC62443
• Target levels consideration based on cost-effectiveness
• Centralized security management with real-time monitoring
• 24/7 global management through help desk

Benefits

• Minimizing the monetary loss risks from cyber attacks
• Cost reduction by simplifying, standardizing, and further integrating security management
• Strengthen the security by complying with industry and enterprise security standards such as IEC62443

Transformation into Data-Driven Operations

Organize workflows to support optimal on-site data utilization

On-Site Challenges

• Little use of camera images and process data
• Unclear work procedures

Solutions

• Organize the collected data and the use to create priorities and roadmaps for data utilization
• Hold workshops to clarify work procedures
• Introduce digital standard operating procedures (SOP) to achieve automation through systems

Benefits

• Operational transform tailored to actual work contents and data
• SOP facilitates skill transfer and reduces the burden of operators

Step1： Organize Data Usage and Work Procedures

Propose workflow improvements using unused data

Before : Frequently remains in the abnormal state

The froth on the flotation cell surface are captured on camera but are not monitored by the operator. The abnormal froth conditions are left unchecked, adversely affecting mineral recovery rates.

After : Rapid detection and response to abnormal conditions

Rapid detection and response to abnormal conditions automatically detects abnormal froth conditions by image-recognizing the camera image. Notify the operator and prompts the operator to respond quickly.

Step2： Work Standardization and Automation

Achieve operational stabilization and early recovery by SOP introduction

Before : The work varies depending on the operators

Operator’s work procedures for recovering from abnormal to normal conditions are inconsistent and vary.

After : Work is standardized and partly automated

Identify and improve the operator’s work procedures, and incorporated into the SOP.
Minimize the person-hours required for recovery by automating works that can be systemized.

On-Site Challenges

• Irregular equipment monitoring and relying on manpower
• Time consuming inspection caused by the vast site area

Solutions

• Automatically collect equipment condition data at all times by utilizing the easy-to-install wireless sensors
• Monitor equipment condition on a dashboard and detect abnormal signs with AI

Benefits

• Reduce the person-hours for human inspection
• Stabilize inspection quality through quantifying and visualizing inspection work
• Prevent sudden, unexpected equipment failure

1. LoRaWAN Gateway
Data collection and transfer to server

2. Sushi Sensor
Measurement of surface temperature and vibration

Framework Proposed by Yokogawa

AOM (Asset Operations Management) is built on three technology pillars: Composability, AI/ML, and Digital Twin. It unifies operations, maintenance, reliability, and engineering to achieve operational excellence.

• Operations
  Operations ensure efficient and effective use of assets
• Reliability
  Improve the assets’ reliability by supporting the intended performance metrics achievement without failures over a specific period under specific conditions
• Maintenance
  Asset maintenance effectively minimizes operational downtime and associated costs
• Engineering ​​​​​​
  Develop and optimize asset designs and processes to ensure efficient operations and compliance with standards, and to meet operational demands and future modifications

AI Is Evolving from Assisting Humans to Collaborating with Humans

AI agents not only perform specialized tasks to achieve business goals, but also communicate and coordinate with other AI agents to enhance problem-solving capabilities. This means that AI agents behave in the same way as operators and engineers have done until now.