Improving Mining Efficiency
<span style="font-weight: bold;">Bentley's connected data environment delivers step changes in productivity for mining operations.</span><br /> <br /> Mining companies often talk about using technology to improve efficiency and survive in this industry, where margins are razor thin. Two nominations this year illustrate how Bentley's comprehensive modelling environment, managed through a connected data environment, is enabling innovation and significant cost savings in this industry. Minerals are recovered from tailings through crushing, grinding, and flotation. <br /> <br /> Outotec's latest innovation in minerals processing is an advanced modular flotation cPlant comprised pre-fabricated modules inside container-sized steel frames. Outotec designed the modules so that they are easy to transport and install, and can be quickly integrated with an existing plant. This design also enables the flotation cPlant to be transferred from one site when a concentrator plant comes to the end of its lifecycle. Outotec also offers a large variety of services, including maintenance support, and that is why it chose to implement AssetWise Asset Reliability to facilitate preventative maintenance and to minimise unplanned downtime. Outotec offers this service to any customer procuring the flotation cPlant. The maintenance plan covers the entire flotation cPlant from production process performance to equipment reliability, leveraging failure mode effect analysis and asset criticality identification. By maximising reliable production, the maintenance plan is expected to increase the plant net production yield by 3 to 5 per cent.<br /> <br /> JSC Kovdor Mining and Processing Plant (GOK) is located in the south-west of Murmansk Region's Kola Peninsula, 20 km from the border with Finland, a region with a harsh climate where temperatures can drop to -30oC in the winter. The mine is Russia's second largest producer of apatite concentrate and the world's only producer of baddeleyite concentrate. The total area occupied by the industrial facilities is 2,500 hectare, of which 450 hectare is dedicated to open-cast mines, and 85 hectares is occupied by the homogenisation and reloading stockpiles of raw materials and finished products.<br /> <br /> Surveying the mine's production and raw materials stockpiles is a critical function for operational productivity as well as for safety (avoiding stock pile collapses). The mine decided to replace a laser scanning process, which was labour intensive and not practical for inaccessible areas. In January 2017, GOK began to use drones and ContextCapture software to survey the mine. The simplicity of drone operation and the reliability and mobility of the drones (even in snow storms) allowed GOK to cut the time required in the field in half. Additionally, ContextCapture's ability to immediately generate ready-to-use data increased the efficiency of the survey operations by 40 per cent. Since drones can be used to survey previously inaccessible places, GOK has been able to start up production in the eastern part of the mine that had been deemed inaccessible due to a stockpile collapse in 2015. This expansion will allow them to develop 155 million tonne of ore and generate a profit of 2.5 billion rubles.<br />