Success case - 4Sight Automation secures R40 Million project with Zimplats

ABOUT THE PARTNER

Zimplats is the leading mining company in Zimbabwe specializing in platinum group metals such as platinum, palladium, rhodium, iridium, ruthenium & osmium.

The company’s vision is to be the safety and cost leader in the platinum sector with sustainable growth in production whilst generating superior returns for the benefit of its stakeholders.

BUSINESS REQUIREMENT

The mine is intended to replace production from the Ngwarti and Rukodzi mines. A brand-new ore handling system needed to be built. Zimplats needed to know if this is feasible, this meant that the new mine needed to be evaluated.

Due to the COVID-19 pandemic, travelling to the site to complete the commissioning of the evaluation was prohibited. Zimplat needed a way to commission the first phase of the project remotely. The next step would be to implement the necessary automation solutions that would also be gathered from the evaluation.

WHY 4SIGHT | AGE?

Choosing 4Sight Age (Age) was an easy decision for ZImplats. Over the past 15 years, Age has been supporting and successfully implementing automation projects for Zimplats.

Not only does Zimplats have full confidence in Age as advisors, but the company also understands Age’s capacity to deliver large automation projects and their superb capability to manage these projects.

As Age has certified engineers on the Siemens control system, Zimplats knew it was the perfect time to call upon their trusted partners.

SOLUTION

Currently, in phase 1 of the project, Age has already finished designing, developing, manufacturing, installing and are in the process of commissioning the new ore handling system for the Mupani mine.

The first step for Age was to assess Mupani and give accurate details of the feasibility to replace the production of the Ngwarti and Rukodzi mines with Mupani portal 6. The COVID-19 pandemic made this difficult, but Age built a site automation network (Industrial Ethernet Network) that can be accessed via a firewall. This enabled the engineers to continue commissioning remotely.

The design included the C&I design and drawings for the whole project including the hardware and software. Once the clients approved, Age provided the hardware needed namely 5 ore handling conveyors, a crusher, an apron feeder, and two stockpiles.

To make sure that everything works properly, a number of software and motors needed to be installed. It also needed to be integrated with the existing control system.

Age implemented Siemen’s PLC software (for controlling of the machines), a Siemens HMI is also installed, this is software that allows humans to engage and interact with machines. A Profibus field communication network (a data and communication system) is installed, saving enormously on cabling and installation costs.

Age installed Intelligent motor controls called SINAMICS G120 drives and SIMOCODE Pro Motor Management. For conveyor safety and control, a Dupline safe is added to identify which switch has been pulled and to shut down the conveyors. A BRS2 Belt Rip Detection System is used to Detect longitudinal rips as soon as possible to increase the conveyor belt’s productivity.

BUSINESS BENEFITS

The biggest challenge that this project presented is the fact that it needed to be done in the time of a pandemic. Age is now able to do the commissioning remotely, and Zimplats can look forward to a complete automated ore handling system. This means that the physical presence of workers that would usually be there to control the machines can be used for other purposes, whether it is for upskilling or to work from home. In turn, any safety issues and human errors are removed. Despite the COVID-19 pandemic, the project will be ready to move on to phase 2 in May 2021. The way the system is developed ensures maximum productivity and profitability. The implemented solutions provide good safety measures and can be tracked and controlled thoroughly.