Mineral processing: a eulogy for analog

Analog is finally dead when it comes to process technology in mining.

Is this something of a future statement? No. We are now at the tipping point where analog technologies are no longer the ‘easiest’ or the ‘most reliable’ source of data in mineral processing plants.

The mining industry in Australia is undergoing a significant transformation driven by advances in instrumentation, process control and automation. Why? Maximising operators’ environmental, sustainability and governance (ESG) credentials has become critical. Financial approvals for projects are now contingent on implementing class-leading initiatives for improving efficiency, safety and environmental sustainability. Share prices of mining companies that focus on building a ‘green’ brand perform better than those that don’t.

This is one of the main drivers for the rise of big data, Industry 4.0 and advanced sensing in mining, which gathers additional data to support these automation-driven initiatives. Historically, one of the primary challenges in modern process automation is integrating the diverse data generated by smart instrument sources into a unified system. In processing plants, achieving real-time data connectivity across various instruments and systems is critical. Of course, this was possible with analog systems; however, these days sensors can deliver more than 10 variables, whereas in the past it was just one.

The implementation of advanced communication protocols like industrial Ethernet and wireless solutions can significantly enhance this data integration and capture. These protocols enable seamless communication between field devices and control systems, providing operators with comprehensive visibility and control over their processes. With sensors now available from leading vendors on the latest generation of digital communication configurations such as Ethernet-APL, it is much more cost-effective to utilise digital devices for every application.

Leading mines have already accomplished an automated, digitally connected mine and are reaping the benefits that all this additional data brings. In a major copper processing plant in South Australia, integrating industrial Ethernet-enabled flowmeters and pressure sensors improved data accuracy and reliability in their water distribution network. The integration facilitated real-time monitoring and control, enabling the plant to optimise throughput and reduce energy consumption. Integrating self-monitoring and verification software within the sensors allowed continuous diagnostics and scheduled, remote verification of the measuring instruments. This facilitates predictive maintenance, eliminating calibration requirements and ensuring compliance with stringent site standards. That is simply not possible with older analog devices.

One way to use this additional data from such smart sensors is to improve the reliability of each measurement point by implementing an advanced maintenance philosophy such as predictive maintenance. Predictive maintenance is revolutionising asset management by enabling early detection of potential failures, thus reducing downtime and maintenance costs. Data from sensors from vendors that focus on R&D in their sensor and instrumentation portfolio can be rich enough to bring valuable insights to optimise maintenance. Of course, all this is only possible via digital outputs.

The latest greenfield projects that are being carried out by leading mining companies passionate about their public image, safety record and profitability are adopting this latest technology, and you’ll see it in their culture when you interact with them. Next time you’re working on a project, why don’t you ask yourself: “How can I further automate even the smallest sensing requirement with today’s technology?” rather than just copying what had been done before, and before, and before?

*Taylor McKertich is the Regional Industry Manager for Mining, Minerals and Metals at Endress+Hauser Group in the Asia Pacific region, with a focus on process improvement, operational excellence and engineering solutions in the industrial automation field.

Top image credit: iStock.com/Vladimir Zapletin