Risk management for Mining Industry - MMEA Final Reportmmeafinalreport.fi/files/WP5 Risk management for Mining Industry.pdf · Quality control & anomaly detections Data operator &

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Risk management for Mining Industry

Esko JuusoControl EngineeringUniversity of Oulu

MMEA Mining KeydemoOulu 8 September 2015

Outline• Mine processes and water• Measurements

– Process & environment, laboratory & online

• Water balance– weather, rainfall, snow, hydrological forecasts,

3D

• Automation & monitoring concept– Combined measurements, trend analysis, SPC

• Risk management• Services• Conclusions


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Unit processes


Mining

Crushing

Grinding

Stagewiseflotation

Agglomeration

Piling

Bioheap leaching

Reactors- Stagewise metal

extractionDrying

Chemistry

Bio

Chemistry

Mechanical

Water basinsTailings Clarification

Concentration

WaterRecycle Disposing

Process flow sheet


Machines and process equipment

Water

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Water handlingMine water• Water supply• Process water

– Mining & mineral processing– Metallurgical extraction

• Wastewater (disposed)– Contamination– Wasteà drainage, leakage

• Ground/Surface water– Rainfall– Melting of snow

Treatment and recycle• Remove harmful

chemicals– for processes– for environment

• Explosivesà nitrogen+ suspended solids

• Settling ponds• Tailing dams

(=crushed stones +chemicals) & othersolid materials


Measurements

Process• flow (water, sludge &

chemicals),• pH, density, redox, volume,

mass, temperature,• level, dosage, air, pressure,

gas flow, location, speed andconductivity,

• metal concentrations,• suspended solids

Environment• basin levels, suspended

solids, flow, temperature,metal concentrations, airquality, pH, electricalconductivity

• dust, particle measurements• moss analysis


Note! Processes are mine specific,i.e. developed for specific ores and metals.

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Laboratory measurements• Highly accurate in principle• Time-consuming & tediousà Expensive• Sampling in large areas• Infrequentà hazards if leakages

– Even small concentrations of heavy metals canbe very harmful

• Environmental measurements:– Regular monitoring of wastewater required– Measurement locations– Sampling frequency: weekly, monthly, yearly


Online measurements• Continuous & real-time• Problems

– Reliability & accuracy(malfunctioning periods)

– Applicability– Speed– Cost– Cleaning requirements– Maintenance

• Rough and varyingoperating conditions– Process and weather

• Process measurements• Condition monitoring

(machines and processequipment)

• Environment• Approval from

environmentalauthorities?

• Environmentalregulations


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Waste rock deposits

Storages ofchemical substances

Tailing dams

Water basins

Wast areasà measurement placing?

Special: heap leaching piles

Dynamic modellingà Forecasting?

Geographical data• Laser scanningà 3D data

– airborne, terrestrial, mobile– unmanned airborne vehicles (UAV)– hyperspectral lidar system

• Digital terrain models (DTM)• Digital surface model (DSM)

– sensor quality– imaging system– atmospheric, illumination, and wind conditions

during the data collection

• Detect environmental problems


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Weather forecasts


Finnish meteorological institute (FMI)provides information about air quality,wind, temperature, climate, rain,snow depth, etc.

Hydrological forecasts


Finland’s environmentaladministration (SYKE) provides- Hydrological maps for water level,

daily precipitation, waterequivalent of snow, etc.

- Warnings for flood and water level,precipitation, snow load

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mmea.fi


Measurementsà Automationà Risk Management


Measurements

Intelligentanalysers

RiskManagement

EnvironmentWeatherHydrological forecasts

Mine processes

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Automationà Integration


Mine processes

Environment

MonitoringControl

RiskManagement

ConditionMonitoring

Measurementsà Intelligent analysers


Signal processing- Derivation & Integration- Filters- Blind source separation

Feature extraction- Norms- Histograms- Variable selection- Grouping

InterpolationUncertainty handling

Signals

Process measurements

Process measurements

Laboratory analysis

Nonlinear scaling- Normalisation- Asymmetry- Scaling functions

LE models- Steady-state- Dynamic- Multimodel

Intelligent indices- Indirect measurements- Stress & Condition- Trends- Quality control

Intelligent indices

- Indirect measurements- Stress & Condition- Trends

• Process Cases & Faults• Predictions• Anomaly detection

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Nonlinear scaling


Measurements

Meanings

Expertknowledge

- Linguistic levels can translated into numbers- Natural language

Machines: cumulative stress

• Daily number index valuesHigh stress à strong harmful effectsà wear, fatigue

Normal stressà moderate effect

Low stressà negligible effectVery long smooth operation

17280126024 =××

Note: Left Vertical!


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Generalised SPC


Trend analysis


åå-=-= +

-+

=k

nkij

L

k

nkij

S

Tj

LS

kXn

kXn

kI )(1

1)(1

1)(

Change of trend index

Trend index

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Risk management


ControlDecision makingControl

Decision makingProcess controlDecision making

ModellingRisk identification

Risk analysisHigh-level control

Diagnostics

Performance analysisEnviromental measurementsAdaptation

Intelligent analyser(Software sensor)Intelligent analyser

(Software sensor)Intelligent analyser(Software sensor)

Measurementtechnology

Process

Measurements

Modelling

Open data

Risk management






Diagnostics





Process

Measurements

Modelling

Open data

Process insight, weather, water balance

Intelligent analysers: traffic lights, trendsNew measurements

New measurements

Forecasting

Globalmarkets

Situation awareness

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MMEA Mining Key Demonstration


Remote Sensing- Radar- Lidar- Airborne

Measurements- Solution studies- High performance• on-line monitoring

Data Management- Data Sources- Processing- Testbed

EE Management/- Monitoring methods- Decision Support

EE ServicesConcepts

Sampling and process emission

Mining water solutions

Atmospheric boundary layer sensingwith radar, lidar & airborne Instruments

Weather observations & forecasting

Quality control & anomaly detections

Data operator & data sources

Modelling (water, weather)

Monitoring methods and tools

Monitoring and management frameworkfor early risk management

Decision support systems

3D modelling

Probabilistic regional forecasting

Smart Applications in Industrial Internet

Thing

Thing

Thing

Act!

Store,analyse,refine,etc.

Local integrated applications!

Utilise!

Local processingà Efficient local useà Less data transfer

Things

Services





Diagnostics





Process

Measurements

Modelling

Open data

GSPC & Trends

I2oSIoT

Experts

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Conclusions• Process measurements à real-time• Samplingà Laboratory analysis• More real-time measurements• Combine measurements + trend analysis + GSPC• Monitoringà Control & Optimization• Forecasting + Risk identification• Situation awareness• Services


EnvironmentMine area

Mine processesOpen data

Participatoryobservations

Documents

Risk management for Mining Industry - MMEA Final Reportmmeafinalreport.fi/files/WP5 Risk management for Mining Industry.pdf · Quality control & anomaly detections Data operator &