How did you overcome the challenges posed by the pandemic?
2020 was a year of extraordinary efforts to maintain operations, with a strong focus on pandemic control and management. Despite these challenges, we are very pleased with the results as we maintained our growth in the midst of the outbreak. Our construction company witnessed an increase in sales, despite being one of the most challenging as a 1,000+ person operation, but thanks to safety protocols and employee commitment, the result was excellent.
The technology business also saw significant progress. In 2020 we introduced robotics in mill relining, which is critical from both a production and human risk standpoint. We advanced technology at Minera Los Pelambres with AMSA. This is a pioneering application worldwide and we are pleased to have been able to demonstrate the performance of the robotic arms. This technology will go live this year with AMSA, which will be a global milestone. We are also working on the same technology with Minera Escondida.
What advances have you made with robotics?
In Peru, we have a very strong position, for example, in Antapaccay, as well as in the ports of Matarani and Callao. We have an interesting foundry application at Magotteaux in the U.S., which reduces the need for people in the assembly of molds in foundries.
On the other hand, last year, we contacted potential customers in Europe, particularly foundries in Finland and Sweden, for melting furnace applications. We are in the implementation phase at BHP’s Olympic Dam in Australia and are looking at applications for smelters in France. We have also presented our developments to Anglo American’s worldwide foundry specialists.
How are the company and the industry changing to incorporate more technology in mining?
In other industries, such as automotive, robotics is highly developed, but in mining it had a very low level of penetration until last year, when the Covid-19 crisis prompted a new approach focused on increasing productivity and reducing risks. The applications are multiple; for example, we are currently developing a robotic washing process for large mining trucks.
Internally, we are making significant changes in the company to respond to new business opportunities. We signed an agreement with the Universidad de Concepción to incorporate artificial intelligence in the application of robotic technology to the change of mill liners. With this we are going to structure a whole artificial intelligence program for the company. We are also developing a global monitoring center for all the robotic operations we are implementing. This is a process in which we already have relevant experience. Years ago, when we developed the plant maintenance services company, we installed a monitoring center for the mills and their motors in different operations in Chile, Argentina, Peru and Brazil.
Do you think Chile will become an important exporter of mining technology?
Chile, due to its strong and consolidated mining industry, is becoming a pole of technological development. We are a company with an innovative vocation, and innovation has been a strategic pillar from the beginning.
Robotic applications have been operating for several years in the US and Peru, and we see applications in Australia and Europe. In the group, we already have a unique world-scale robotics development center for mills.
Where do you see the greatest growth potential for the company in the coming years?
The copper industry will witness bullish projections due to electromobility and technological developments that depend on copper, which will continue to increase demand. Our vision is to become a leading global robotics company in the mining and heavy industry sectors. To achieve this, we have transformed ourselves into two entities: on the one hand, we are starting up a company specialized in the application of robotics in mills. On the other hand, the core robotics company, MIRS, has been reinforced with new executives for international business development, as we recently opened the MIRS office in Australia.
Written by rcd_admin, July 24th, 2021 | Comments Off on Interview with Mr. Hugo Salamanca
Thanks to the implementation of robotics, Escondida | BHP was able to reduce work time by 30%, in which, at a speed of two meters per second, it can perform a nut change automatically and without the risk of accidents.
Robots are here to stay. We have seen them serving restaurants in Japan and exploring Mars, but now they are the new companions of the mining industry in Chile.
Escondida | BHP is testing this technology to optimize the maintenance of the mining mills, which for a worker to change the liner plates and nuts manually takes about 72 hours, and robotics managed to reduce the time by 30%.
Thanks to its precision and safety, the work performed by the robot at a speed of two meters per second does not present any risk of accidents in the ball mills of Escondida’s Laguna Seca concentrator.
Robots have been in mining for a long time. The aim is to keep operators away from dangerous tasks and adverse environments. The company MIRS, who in 2005 began to develop this technology, of which one will be able to perform tasks that involve greater risks, such as handling tools or heavy plates, or even getting close to fire.
Likewise, MIRS Development Manager, Luis Baeza, explained that the objective is to create a flushed body capable of making its own decisions, “we joined our mining knowledge with robotics to cover a need”.
A study conducted by Randstad showed that 55% of Chilean workers believe that due to the implementation of automation, job offers will decrease. However, its application responds to the risky tasks that humans are exposed to in order to reduce future accidents.
“This whole issue of automation helps us, it is the empowerment of our people (…) Each plate weighs between 80 and 100 kg, it is a difficult weight to handle. In this case, the interaction of our people with this potential risk is zero,” explained Eduardo Romo, BHP’s Electrowinning production supervisor.
Written by rcd_admin, July 24th, 2021 | Comments Off on Robotics in mining: These are the machines that deliver safety and enhance the work
In order to learn about new robotic technologies applied in mining, delegations from both companies visited the modern Robotic Development Center of this national company, a subsidiary of HighService Corp. The delegation from the state-owned copper company was headed by its Executive President, Octavio Araneda, while Teck was headed by its Maintenance Manager, Dave Adema.
Codelco and Teck made important visits to the facilities of MIRS, a subsidiary of HighService Corp. that specializes in designing, developing and implementing robotic products and systems for the mining industry. “It was an opportunity to show everything we have advanced with our applications to two large mining companies such as Codelco and Teck”, highlights Hugo Salamanca, President and CEO of HighService Corp.
At the technology center, a live, full-scale demonstration was given of the robotic mill liner change, the final application of which completely automates this activity, guaranteeing safety, productivity and speed.
A long history of working together
Hugo Salamanca emphasizes that the visit of Codelco’s senior executives had a special significance because the copper company played an important role in the creation of MIRS in 2007: “We worked together to raise business opportunities in robotic technology in the different processes of the value chain”.
In previous years, Codelco has acquired MIRS technologies for the Radomiro Tomic Division, the El Salvador Division and the Ventanas Division. Hugo Salamanca says that during the visit, a map with 25 opportunities where robotic technologies can be incorporated was presented to the executives of the state corporation. “Octavio Araneda was pleasantly surprised with our advances. He stated that robotics is a reality, and that the Corporation must adopt a determined plan to deepen the digital transformation already underway,” he says.
Strong technological momentum
Equally successful was the visit of Teck’s senior executives, who showed great interest in the robotic solutions offered by MIRS. For example, regarding the robotic lining change, due to the benefits and the high intrinsic impact of implementing this type of technological applications in the Quebrada Blanca Phase 2 Project. Or regarding the robotic truck washing system, a solution that eliminates the risk of potential accidents and complex environmental conditions, and improves washing times, thus optimizing the use of water resources. Hugo Salamanca concludes: “Important expansion projects are coming. And these visits reinforce that the commitment we made years ago to robotic technology in mining has gained strong momentum”.
Written by rcd_admin, June 24th, 2021 | Comments Off on Codelco and Teck learn about new robotic applications for mining developed by MIRS.
The application, developed in Chile and unique in the market, reduces maintenance hours by 40 to 50 hours, eliminates operator exposure to risks, improves equipment control, and provides greater reliability to mining concentrators.
A faster, safer and better quality process is offered by the robotic mill liner change solution developed by Mining Industry Robotic Solutions, MIRS, a subsidiary of HighService Corp.
Under the slogan “Nobody in the mill” and after extensive analysis and multiple tests, the national company was able to implement this application that allows the complete transformation of a hitherto manual task into a fully automated one, which is carried out in less time.
“It is a unique solution. There is no alternative on the market that compares to it, since what is available does not eliminate the presence of people in the mill, nor can it be faster,” says Igor Elías, MIRS Milling Business Line Manager.
ADVANTAGES
One of the main advantages of robotic casing changeover is that customers are no longer faced with the dilemma of choosing between safety and speed of operation.
“In terms of safety, we reduced people’s exposure by 100%. We are not talking about developing an administrative procedure or work permit, putting up a barrier or fence, or using a harness, which are preventive measures, but rather eliminating the risk,” he says. In addition, this solution makes it possible to perform tasks up to 35% faster than the current process of
coating changes. “One hour of maintenance represents about US$150k to US$250k of production,” he says.
“It is a unique solution. There is no other alternative on the market that compares to it, as it
that what is available does not eliminate the presence of people in the mill, nor can it be faster,” Igor Elías.
PROCESS QUALITY
Elias points out that another benefit is the quality of the process. “Today, the installation of coatings is done in a hurry and is left to the judgment of the operator. With robots, however, it is possible to establish a level of quality that has never been achieved before. And that allows better operational control of the mill. There will be fewer incidents, which leads to improved reliability,” he says. “The robot controls all installations. It cleans, lubricates, installs, does the calibrated torque, delivers a digital certificate of the bolt and moves on to the next one. And all of that can be verified online,” he explains.
To realize this solution, MIRS created in 2019 a division specially focused on liner change, with close to ten industrial tests performed at customer sites to date. In addition, in its facilities it built two full-scale SAG mills of 36 and 38 feet, and one ball mill of 24 feet in diameter, which has allowed completing more than 16 months of continuous tests on full-scale equipment.
SUPPLY AND PROSPECTS
The company’s offer covers both robots that go on the outside and those that operate inside the mills. The former are already commercially available, so any customer can request an evaluation to specify the system they require, and proceed to implementation in a safe manner.
While the inner machine is at a preliminary stage, in the middle of the last stages of development validation to proceed to manufacturing.
In terms of contracts, the company has made progress with two large customers in Chile, and is in talks with three operations located in Peru. And through its offices in the United States and Australia it will begin a strong sales campaign, so its expectations are very high. “And no less relevant is that the robotic coating change is not only made in Chile, by Chileans and with local master craftsmen, but it also has the merit of solving technological problems that until now had not been solved in any country,” concludes Elías.
Written by rcd_admin, April 01st, 2021 | Comments Off on MIRS projects high demand for its robotic solution for mill liner changes
– Through its subsidiary MIRS, which designs and develops robotic products and systems for the mining industry, the company positions and continues to create solutions that guarantee greater safety and efficiency in the sector’s production processes.
HighService Corp has become an incubator of new business lines, especially through its subsidiary Mining Industry Robotic Solutions, MIRS, which designs and develops robotic products and systems for mining.
“We are pioneers and rank first worldwide in robotic solutions in mining. This experience has allowed us to meet specific needs, i.e., to develop customized solutions that guarantee greater safety and efficiency in the sector’s production processes,” says Javier Espinoza, Vice President of Strategic Business Development of the company.
The executive recalls that “Foundries, for example, are extremely risky because workers are exposed to manual operations at high temperatures as well as to toxic gases. We have identified an opportunity to apply a robotic solution that reduces risks and guarantees that the process is carried out with the required quality”. This is the automation of the opening and closing of slag passages of the concentrate melting furnaces, which also offers greater reliability and control of the process.
“We began to apply it at Chuquicamata a decade ago, and we have been optimizing and improving it over the years,” says Espinoza.
He emphasizes that “today we are seeing a growing interest from smelters in our solution, not only in Chile but also abroad. We have already carried out feasibility engineering in Finland, Sweden, Australia and South Africa.
Espinoza says that another business line with high potential is the robotic washing of extraction trucks. “This activity is very complex in Chile because many of our mines are located above 3,500 meters above sea level and face extreme conditions,” he says.
“The mining trucks need to be washed before entering maintenance. But since there are environmental conditions such as mud, ice and snow, they must be washed with a large flow of water, in circumstances where water resources are scarce, and with a very high pressure that is a high risk for people,” he warns.
For this challenge, MIRS designed a robotized washing slab for trucks that adapts to different sizes, acts efficiently without exposing the maintainer, and reduces the consumption of fresh water. In the mining area, “we are also talking with mining companies and suppliers to develop a robotized fuel loading system, which will increase safety and allow better control of supply”, he adds.
More innovations
The executive highlights that at the request of a gold mining company in Argentina, MIRS is developing the world’s first robotic equipment for harvesting and washing filter presses. “Due to environmental and labor regulations, the client needs to remove operators exposed to mercury gases, and we offered them a robotic solution that allows them to make their operation viable. We believe that this robot will revolutionize gold production plants,” he says.
Espinoza recalls that MIRS developed the only robotic equipment in the world designed to peel off initial sheets produced in electro-refining processes. The solution was applied at Codelco Ventanas and at Asarco Amarillo, in Texas, USA. “Since only our company offers this type of robotic system, we were recently invited by a large smelter in Europe to automate its refinery,” he says. The executive adds that we see significant growth in MIRS’ “customized” solutions, as they allow customers to access the benefits of robotics at any stage of their value chain without having to change or invest in new production processes
Written by rcd_admin, March 24th, 2021 | Comments Off on HighService Corp and MIRS expand robotic solutions portfolio developed as “tailor-made suits”
In Peru, the company was selected to present on the challenges of digital transformation and the scope of automation and robotics as a way to stay relevant in the competitive mining market.
While the mining industry has the capabilities and interest to constantly innovate, it still has a long way to go to top the list of technologically advanced industries. While other industries lead the way with highly automated operations and low accident rates, many processes in mining have been carried out in the same way for decades. However, several players have dared to break the status quo, becoming excellent case studies regarding the implementation of disruptive technologies.
Based on what has been evidenced in the industry, Camilo Rodriguez, Business Development Manager at MIRS, addressed the past context of technological advances and robot implementations, supported by the experiences of MIRS and its portfolio of robotic solutions implemented in mining. The event took place in the context of Perumin, the second largest mining convention in the world, held in Arequipa, Peru, from September 16 to 20, and organized by the Peruvian Institute of Mining Engineers.
In a first stage, the paper written by Camilo, “Digital Transformation and the scope of robotics in the Peruvian market. A key to differentiation and survival in mining, Automation hand in hand with Robotics”, was selected among the finalists to have a space in the final stage of the exhibition of the Technology, Innovation and Sustainability Forum (TIS Forum) of the event. The presentation, based on the paper, focused on the challenges and advantages of incorporating technological innovations in the mining industry, aiming at an invitation to innovate concretely.
To introduce the topic, he explained that robotics is a branch of automation that has a direct impact on the productivity of industries, reduction of operational costs, increase in the reliability of processes, and improvements in the health and safety of workers.
“Trial and Success.”
Supported by a 2017-2018 report prepared by Ernest & Young, a leading audit and consulting firm, which points out that in the mining and metals industry there is a clear disconnect between the power of digital transformation and the successful implementation of its technologies. Camilo Rodriguez began his presentation by identifying the difficulties in implementing technology and in particular robotic systems in mining, noting, firstly, the technological barriers when you have the need and the opportunity, but the technological resources are not yet available.
“Technology, in general, is governed by Moore’s Law, which talks about every two years the number of transistors in a microprocessor double, which means that every two years the capacity of computer systems doubles, and that applies to almost any technological advance,” he explained.
In the case of MIRS, Camilo points out that the key has been the development of know-how and learning based on trial and error over the years as a leading company in the implementation of robotic systems that were not originally designed for highly variable environments and where contamination of different types affects any system, as happens in mining. This has led to the implementation of higher technology peripheral elements and the application of artificial intelligence tools that can overcome this type of difficulties to approach the performance of the same systems that are implemented in industries with a high level of control, such as the automotive industry.
Another barrier he identified in the adoption of new technologies is the target market, since, in general, mining companies do not risk investing and pioneering innovation, but wait for others to implement solutions to see their results before adopting them. “Failure in a maintenance or operating system in mining is measured in millions of dollars in losses, that is why risk levels are understood to define the market as early majority or pragmatists and not early adopters. Statements such as “Seeing is believing” or “Where have they been installed before” are common barriers,” said the MIRS executive.
He also mentioned the labor market barrier, since systems that advance hand in hand with Moore’s law produce the so-called “technological unemployment” which, in turn, leads to social and union problems. In this sense, Camilo Rodriguez emphasized the need to create new intelligent jobs, which demand more brain capacity than physical strength, as a challenge to be solved jointly by the client and the workers, supported by suppliers, to seek retraining and relocation of human resources. To further support this effect, suppliers such as MIRS offer training so that customers can improve the skill levels of their workers.
Finally, he referred to the economic barrier and its importance in the implementation, because after the design process, any technological system that revolutionizes a process, as is the case with robotics, may end up in an operation that differs from what was planned, since the principle of Trial and Error governs. Given this and considering the mining market as Early Majority, suppliers must have sufficiently strong financial backing to be able to generate substantial changes in technological advances.
“That is why mining companies must work hand in hand with suppliers, so that this “trial and error” method becomes more of a “trial and success” method, establishing cooperation to achieve better results, based on the co-creation of these systems,” he said.
More than strength
In relation to how the industry adapts and makes the Digital Transformation its own, the presentation mentioned a report by Ernest & Young that is based on a survey of nearly 700 companies and detected 3 interesting factors in this regard.
Firstly, it indicated that the guidelines emanating from the corporate segment and from the boards of directors are not always clear and do not always go down effectively to the local management to exercise and make them understand, with the correct funding, the need for technological implementation. He indicated that these remain very much in ideas or objectives that are too broad but are not implemented in practice because the information is not delivered effectively on how to implement a clear technological roadmap.
Secondly, he mentioned the risks present in local management, “If a plant manager, for example, decides to adopt a technological innovation and that innovation fails and generates millions of dollars in losses for the company, his job will be at risk. The need to maintain job security for local management sometimes hinders the advancement of technological improvements. Of course, you can always find local managers who are daring and are key players in the industry,” said Camilo Rodriguez.
Finally, he pointed out that mining companies tend to buy a ready-made and proven product, without necessarily understanding the technological and economic complexities of its maintenance and implementation.
“The lack of joint work, of co-creation, means that technological innovation processes on the part of suppliers, who often do not have financial backing as MIRS has had during these 15 years, fail before being tested,” said Rodríguez.
Among the exceptions, he mentioned the MIRS robotic solution installed at the Impala Terminals plant in Peru, which automates the process of extracting representative samples of ore from the trucks, reducing the risk of error and bias in the process to its minimum expression in one of the most important processes, the sampling of the final product, which includes all the added value of the production process.
He also presented the Internal and External Mill Maintenance Robot (IMMR and EMMR), the new MIRS robotic solutions for liner replacement in SAG and ball mills, a pioneering process never seen before that eliminates the intervention of people and eliminates the risk of accidents in one of the most dangerous tasks in the mining industry and in the world. Focusing on the future and based on studies by Oxford University and different bibliographic resources, Camilo Rodríguez pointed out that it is expected that in 20 years the Singularity will be reached, that point at which artificial intelligence surpasses human intelligence. “We must be prepared for that,” he indicated. “It implies understanding that maintenance and production systems in mining will not only have an obvious deployment of force, but that they can also start to think, and that forces important software improvements, to perfect them and allow them, for example, to be able to correct process failures in situ.”
Written by rcd_admin, October 14th, 2019 | No Comments »
A unique piece of equipment in the world responds to one of the biggest technological challenges in the mining industry, by executing the change of liners at a speed never achieved, with high standards of quality, efficiency and safety.
MIRS launched a revolutionary robotic solution developed entirely in Chile for the lining of SAG and ball mills, at an international event that took place on September 5 at the industrial testing facilities owned by the company, a subsidiary of HighService Corp. in San Bernardo.
The main players in the mining sector, led by the Minister of Mining, Baldo Prokurica, and more than 40 mining and engineering company executives from Chile and Peru, had the opportunity to witness a full-scale model of a 36″ SAG mill and the operation of the EMMR (External Mill Maintenance Robot), the world’s first fully automated system that performs this operation autonomously and without human intervention.
The launch confirms not only the progress and high level of technological development achieved by MIRS worldwide, but also represents the biggest breakthrough in recent times in automation for the mill liner change process in the mining industry, in terms of safety and quality.
“Mining is challenged to change the way we extract and produce metals and minerals. It is now when the industry has the possibility to transform its processes and resume its productivity and competitiveness rates, and that is why the incorporation of technologies and innovations are totally necessary to face it, in a process where robotics plays a very important role,” HighService Corp’s President and CEO, Hugo Salamanca, told the audience.
40 hours less
The process of changing liners is a task that, in the case of SAG mills, must be performed every three to six months and, in the case of ball mills, every 8 to 18 months, depending on the hardness of the ore.
Until now, the only way to execute it was through manual work, performed by a team inside and outside the mill with the support of manual hydraulic machines, in a high-risk environment that constitutes the main cause of a concentrator plant’s mill unavailability.
“Minimizing the time to run the mill liner is a condition that the industry has always demanded,” says Igor Elias, MIRS Mill Reline Commercial Area Manager. “This innovation in plant maintenance reduces maintenance times and increases worker safety,” he adds.
To meet the requirements of its customers, the MIRS automated system increases the quality, safety and speed of the operation by replacing manual labor with the collaborative action of robots of up to 6 tons, which operate in parallel at a speed that reaches up to 2 meters per second, reducing the total time of the operation by approximately 40%. “A 100-hour stoppage with the conventional system will decrease to 60 hours with the use of EMMR and IMMR,” says Igor Elias.
This solution presented by MIRS performs all the high-impact work involved in changing liners, but completely automated: removing nuts and washers, removing bolts, cleaning and lubricating bolt threads, installing new bolts, simultaneously tightening two nuts, cleaning bushings and nuts, and normalizing mill for operation, among others.
High impact and versatility
During the launch, a demonstration was also given of how complementary technologies for EMMR work, such as the IMMR (Internal Mill Maintenance Robot) automatic manipulator, the first fully automatic prototype that performs liner changes on the inside of the mill.
Designed to operate in parallel with the EMMR, it automates the removal of liners and bolts from the inside, as well as their subsequent installation, and will perform other activities such as automatic oxy-fuel cutting and high-pressure washing.
“Acting together, the EMMR and IMMR systems will make it possible to fully automate the process of changing internal and external liners of SAG and ball mills in the absolute absence of human intervention in the mill,” says Igor Elias.
Additionally, both systems have the advantage of minimizing the cost of implementation, as they are installed and uninstalled, requiring minimal adaptation of the plant design and without requiring changes or adjustments, as they incorporate multipurpose tools that are compatible with the traditional ones used inside the mill, even if they are not robotic.
Both solutions feature the new MIRS Bolt-Driven technology, which allows liners to be installed and replaced without dropping them into the mill, allowing a free and continuous flow of materials into and out of the mill, and with MIRS Power Strike, which allows robotic liner replacement to be operated with different types of bolting systems.
This system allows the addition of a series of autonomous equipment and platforms, depending on plant conditions. Thus, for example, the transit of new and worn liners is automated from the storage yard to the mill and vice versa, without requiring the support of vehicles such as forklifts.
Written by rcd_admin, September 06th, 2019 | No Comments »
MIRS-a subsidiary of the holding company HighService Corp-is recognized for designing, integrating and manufacturing robotic products and solutions capable of performing in highly variable industrial processes, allowing its customers to incorporate productivity, safety and quality into their processes.
One of the world’s largest mining companies, BHP, published a report on the MIRS Robotic Trommel Blade Handler, which is installed and operating at Minera Escondida.
A high-tech robot that can perform tasks that were previously done manually was developed thanks to an unprecedented joint venture between Minera Escondida, Mirs and FLSmidth.
The MIRS robotic solution allows the automatic and remote replacement of the Trommel blades during programmed stoppages of the SAG mill, tasks that were previously done manually.
This robot improves the safety and productivity of maintenance operations, notes Susan Lasecki, Head of Commercial Innovation, BHP Minerals Americas, in the report: “The robotic arm has safety and productivity benefits. Workers are removed from potentially hazardous situations when changing trommel screens and the time to change each screen is also reduced.”
Applied research, development and technological innovation in automation and robotics constitute one of the pillars for the sustainability of Chilean mining, considering the important benefits that the incorporation of this type of solutions implies.
The “Roadmap for Mining 2015-2035”, prepared by the National High Grade Mining Program based on an open consultation process with different stakeholders in the mining sector.
open consultation process with different industry stakeholders, establishes that the development and incorporation of technology is a critical factor for the sustainability of the sector.
In this sense, it is considered indispensable for Chile to strengthen the incorporation of automation and robotics solutions in the different mining processes, together with developing a greater capacity to generate technologies in this field that can be applied locally, and that can also be adopted in other countries.
Javier Ruiz del Solar, executive director of the Advanced Mining Technology Center (AMTC) of the Faculty of Physical and Mathematical Sciences of the University of Chile, agrees that applied research and the adoption of technologies in this field generate benefits in key aspects of mining development.
“In the case of Chile, the greatest needs in this area are at the mine, smelting and refinery operation levels, since it generates very important benefits in safety, productivity and cost reduction,” he explains.
In the area of mine operations, the incorporation of autonomous or semi-autonomous equipment (trucks and loaders, among others) contributes to increasing operational availability. This can be achieved by reducing shift changeover times and also by reducing wear and tear on machine parts, due to the more efficient use of the machine and the permanent control of its functions.
In the case of smelting and refining processes, Del Solar points out that Chilean mining has a key challenge in the application of advanced processes, where automation and robotics solutions are essential to achieve greater safety and efficiency. “Working conditions in smelters are very complex, due to high temperatures and eventual emanations of hazardous gases, among other factors,” says the AMTC executive director.
Advanced Process Control (APC)
Automation solutions for advanced process control (APC) make it possible to analyze plant processes in real time, with the aim of making decisions that result in higher production volume and quality, increased equipment availability and reduced environmental impact, among other benefits.
For example, the mining company Doña Inés de Collahuasi is using Metso’s OCS-4D software platform in lines 1, 2 and 3 of the rougher flotation circuit. From the application of this system, the company reported a 1.93% increase in its ore recovery, along with a decrease in the deviation and variability of the main controlled aspects of the process: the concentrate grade and the tailings grade.
Loading and conveying equipment
The automation of the conveying and loading processes, either in individual equipment or in fleets, allows operators to be located in safe environments while trucks or loaders operate in hazardous areas, with greater production efficiency.
Sandvik’s AutoMine series includes different automation solutions, which consider the operation of trucks and low-profile front-end loaders in subway mining, and DTH and tophammer drilling rigs on surface.
The company saw a 26% increase in productivity in the case of a mining company that automated its entire fleet of front-end loaders and trucks, due to increased travel speed and equipment utilization rates. In addition, the number of trucks needed to move material was reduced from ten manually operated trucks to seven automated trucks.
Finning Caterpillar’s offering in this area includes the Cat Command line of equipment for subway and surface sites, which allows remote maneuvering of loading, hauling and unloading machines. Along with the aforementioned safety benefits, this equipment is able to operate incorporating the characteristics of the terrain and infrastructure where they work.
The above conditions generate greater operating speed and prevent the machine from coming into contact with the mine walls. In this way, damage to the equipment and wear of its components are greatly reduced.
Indicator monitoring
This type of wireless technology facilitates the remote measurement of indicators such as temperature, pressure and flow in leach heaps, pipelines and installations with complex geometry, among other types of infrastructure.
The development and incorporation of these solutions in a safe, reliable and constant manner requires the application of the worldwide wireless communication protocol ISA 100, developed by The International Society of Automation. This is the case, for example, of the applications developed by Yokogawa, which are used in mining operations worldwide, including Chile.
Particularly, in the wireless and remote measurement system applied to leaching heaps developed by this company, benefits in safety, productivity and cost reduction are achieved, due to the ability to operate at up to five kilometers from the control room; adaptability to various weather and topography conditions; and resistance to temperatures up to 80 degrees Celsius.
Plant control and simulation
The automation of control and simulation activities in plants makes it possible to verify the behavior of these facilities when new technologies or processes are applied, as well as to minimize start-up times and facilitate the training of personnel under high safety standards.
In this area, the ABB Group developed the ABB 800xA control and automation platform, which operates in coordination with simulation software to generate a “virtual plant”, where operating parameters can be tested and the behavior of processes in different scenarios can be reviewed. This solution is currently present in 13 mining operations in Chile, with more than 30 software applications running in them.
Integral Maintenance
Efficiency in maintenance is a critical process in mining operations. In the particular case of SAG and ball mills -which consume an average of 40% of the plant’s energy-, the incorporation of robotized equipment and processes reduces the execution time of these tasks and provides greater productivity in the general operation of the mine.
At the same time, it avoids the work of operators in conditions of high health and safety risk associated with overexertion, possibility of falls, sprains or blows due to sliding material.
In response to this need, Mirs has robotics-based equipment that allows for comprehensive maintenance of these mills, through the removal and retorquing of bolts by means of a high-capacity robotic arm mounted on a traveling carriage that moves around the mill.
Local response
An important challenge for Chilean mining is to strengthen and extend its research, development and innovation capacity to generate local automation and robotics responses with internationalization projections.
To advance towards this goal, in recent years a series of programs and projects have been generated that are contributing to consolidate a specialized ecosystem in this area, whose main objectives are:
Increase the availability and variety of sources of financing and capacity building for suppliers interested in developing applications for local and international medium-scale mining.
Extend communication and cooperation spaces between the public sector, mining companies, research centers and suppliers to facilitate the incorporation of this type of innovation.
Promote interoperability, which allows equipment and systems from different suppliers to work interconnected under the logic of open technologies. Advance in the availability of professionals and technicians capable of working in specialized teams, during the different stages involved in innovation focused on automation and robotics.
Written by rcd_admin, February 24th, 2017 | No Comments »
In just ten years of existence, betting on innovation and development of Chilean technology, the company MIRS has positioned itself as a leader in robotic solutions for mining and heavy industry, aiming decisively to the optimization of resources by its customers.
This Chilean company, leader in the robotization of mining processes, is ten years old. Its goal is to continue creating new solutions, especially focused on Industry 4.0.
In just ten years of existence, betting on innovation and the development of Chilean technology, the company MIRS has positioned itself as a leader in robotic solutions for mining and heavy industry, aiming decisively at the optimization of resources by its customers.
“Our strategic vision is to be able to lead robotization processes in highly variable processes in mining and heavy industry, so we have focused on strengthening our engineering and development area with the best human capital available in the market. The ultimate goal will always be to ensure that each of our machines is capable of exceeding the process specifications and, with it, the customer’s expectations”, explains Igor Elías, Commercial Manager of MIRS.
How would you define the role that MIRS has had and has today in the industry?
MIRS is probably one of the few national companies that export technology developed and patented in Chile all over the world, with offices in our country, Peru, the United States and Africa. This ten-year process, driving a robotics company in a country that does not have a strong technological base, has been very difficult, but at the same time it has made us very strong. The role we have in the industry today is probably to serve as a guide to other technology companies that are in the early stages of their history, which we can help through the many lessons learned. This know-how we usually disseminate through presentations at conferences, where we show the challenges of the development, commercialization, and marketing processes of our products and engineering challenges we have faced and how to solve them.
How important is research, development and innovation for MIRS?
MIRS researches, develops, designs, integrates and manufactures all its systems and machines, so R&D is a crucial part of our value chain. Without this function, we would simply have no products, and we would be just a representative of foreign brands or a distributor. This is one of the most important differences between MIRS and other Chilean companies in the technology sector.
What expertise does KUKA Roboter GmbH bring to the company?
KUKA Roboter, along with being a shareholder of MIRS, is one of the largest developers and manufacturers of robots in the world and together we are promoting the concept of mining 4.0. This implies that not only MIRS has the backing of the KUKA brand and its products, but also allows us to have a much deeper technological integration with them, which translates into the exclusivity that KUKA only through MIRS can put its products in mining.
MILESTONES
In these ten years of life, the most successful solutions developed by MIRS refer to two fundamental topics: “In terms of installed base (equipment sold), the solution that has had the greatest impact is the sampling systems for concentrates in maxibags and trucks. Today these determine the quality of almost all the molybdenum concentrates in the country, and soon close to 60% of the lead, zinc and copper concentrates that Peru ships from the port of Callao”, says Igor Elías. In terms of technological development, he adds, another successful innovation is the initial sheet take-off system for the Amarillo refinery in Texas (Asarco, Grupo Mexico), “due to the enormous complexity of the process in which we were involved, along with the logistical challenge of designing, implementing and commissioning a Chilean robotic system in the United States,” indicates the commercial manager. In 2016 MIRS opened an office in Salt Lake City, USA, hoping that this will be a commercial spearhead for the mining product lines and that through it the company will strengthen its entry into the Heavy Industry sector (steel, foundries, etc.) in that country. Another relevant market for MIRS is Peru, where it has maintained relationships with clients since its beginnings, but it was during 2016 when, together with the controlling group HighService, it opened its first corporate office in Lima. “The positive results have been immediate, closing an excellent first year of commercial operations,” Igor Elías stresses.
When asked about the mining industry’s willingness to incorporate new technologies, the executive warns that “mining is one of the industrial sectors that spends the least on innovation in relation to its income, compared to other heavy industries, and that is a debt that is being paid dearly today due to the loss of productivity”. This reality, he adds, was a constant impediment to materialize many MIRS projects in the past, “but today, given the current market circumstances, we have seen an important paradigm shift: finally, mining has had to look to advanced technologies, such as robotics, as the way to recover its productivity and competitiveness indexes. In this sense, we see a promising future”, he remarks.
MILL MAINTENANCE SUPPORT ROBOTS
Recently, in December 2016, MIRS launched a new range of products in which the company has high expectations. This is the line of robots for SAG mill maintenance support (change of mill liners and trommel), the first unit of which was delivered to Minera Escondida. “We are confident that this is a product line with the potential to transform the way we maintain and operate concentrator plants. It has already aroused enormous interest in the mining sector, which has us working hard on new projects,” says Igor Elías, Commercial Manager.
Written by rcd_admin, February 15th, 2017 | No Comments »
