In this digitized world, mining companies must become digitized to keep pace with technology improvement. in mining industry, the software technology has progressed to the point where APC (Advanced process control systems) commonly used as an optimizing engine to maximize profits for a broad range of operating variables.
APC improves process profitability by enhancing quality, increasing throughput, reducing energy usage, enhancing safety and reliability, improve process stability, increasing operating flexibility and reducing downstream unit variability by fewer process upsets. Advanced Control and Optimization benefits are field proven and generate high rates of return on investment.
APC performs a series of process response tests, which collect dynamically rich data with little or no disruption to normal process operations.
One of the biggest advantages of digitizing the mining operations is creating ‘smart mines’ that allow you to reduce your operational costs. Smart mines are mines where the major assets are digitized via embedded sensors that transmit data to a centralized location through a wireless network. This allows operators of mines to save money not just on labor ¬_since human workers are no longer needed to perform data readings on site manually_ but also on cable maintenance because the need for expensive cabling is eliminated.
Wireless monitoring by APC tools which integrated with DCS and plc of mine, cause to predict maintenance accurately and enables companies operating mines to track operating assets, such as dams, remotely and continuously to ensure that they are not damaged, monitor the energy and water usage in whole operation areas to optimize the energy and water utilization.
This digital evolution creates the opportunity for mining companies to fundamentally change the business model, unlocking much-improved customer service and customization, reducing costs in the value chain, improving safety, and creating opportunities for new businesses.
The way a system equipped with #APC work is that APCs sit near the top, executing set points with base-layer controllers (BLCs) such as programmable logic controllers or distributed control systems, In this sense, APCs facilitate communication between system-level controls, subsystems (sensors and instruments), and machinery.
In the #mining industry, for example, APCs communicate with different feed sources to deliver the target particle mix to a mill1 to be processed (below picture). They also help ensure an optimal retention time by controlling the feed rate of ore and water (otherwise known as “ore hardness”). Each real-time controller drives a single controlled variable to a prescribed set point. For example, one controller might adjust the speed of the dilution pump to maintain the desired water flow, which informs the APC assigned to retention time.