More information: www.siemens.com/mining Contact: mining@siemens.com SIMINE Automation and MES For more information and technical descriptions, click on the Support navigation point on our Website. Siemens AG Industry Sector Drive Technologies Mining Technologies Schuhstr. 60 91052 ERLANGEN GERMANY Subject to change without prior notice 08/12 Order No.: E20001-A220-T195-X-7600 Dispo 21662 GD.LD.VM.MIMI.52.2.05 WS 09121.0 Printed in Germany Siemens AG 2012 Seamless integrated solution for the mining industry The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. siemens.com/mining All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners. Answers for industry.
Your challenge Your benefits The SIMINE Automation and MES approach provides minerals operators with solutions for the following challenges: How can I increase my productivity and production even on decreasing ore grades? ensure product quality and handle the complete supply chain to maximize my delivery performance? run the operations with highest availability and safety even on a tight labor market? handle complex assets in remote locations and under extreme environmental conditions? optimize energy efficiency and ensure environmental sustainability? reduce my project risk and achieve a faster ROI on green-field projects or big expansions? Upgrades & migration Integration package units Information switchgear Life cycle & remote services ERP integrated MES for mining Plant asset engineering Energy Industrial security APC optimization The SIMINE Automation and MES approach enables great productivity improvements and immediate financial benefits with: Low risks and fast startup times thanks to one supplier covering everything from field level to industrial IT Optimized asset utilization and Increased operational efficiency through reduced maintenance costs and less unplanned downtimes Reduced project effort due to our modular library approach Compliance with regulatory and quality standard Less energy consumption and environmental sustainability Guaranteed shipping quality and enormous reduction of penalties for ship loading delays MCC & drives field devices Safety integrated power control Scalability Openness 2 3
Our solution SIMINE Automation and MES Enterprise Resource Planning Manufacturing Execution System Automation Seamless solutions for all plant levels available Siemens SIMINE Automation and MES is a comprehensive out of the box solution designed specifically for the minerals industry. It is the result of Siemens experience in both automation technology and minerals expertise and has proven its reliability and efficiency in numerous installations around the world and on each automation layer: Siemens provides a complete field instrumentation port folio for the minerals process. 4 The Minerals Automation Standard is the process control solution for minerals operations based on SIMATIC PCS7 one of the leading DCS systems in the process industry. The out of the box solution SIMINE MES delivers all necessary information and connects the process data to the ERP Level. An ERP scenario for the minerals industry seamlessly integrated in the SIMINE Automation and MES solution secures an optimized implementation process based on a best practice solution. 5
Seamless integrated automation for mine operation The new Minerals Automation Standard offers customized solutions for every automation task in a mine from single equipment to complete control of a mine. Primery crusher overview screen Build upon the proven, universal SIMATIC PCS7 process control system (DCS) from Siemens, the Minerals Automation Standard provides a best in class solution while focussing on the specific requirements of the minerals industry. Functions and features Efficient engineering minerals library A specific minerals library provides a predefined engineering approach for the mine process with typicals for the control and visualization level. In addition a process oriented engineering strategy, more process configuration than engineering, helps to streamline and optimize the engineering process. One system for process and power control The integrated power control for mine operations is based on the communication standard for power IEC61850 and results in cost savings and increased availability. 6 Gearless mill control Vendor package implementation and integration Easy implementation of vendor packages based on a package library. In addition fast and simple integration of vendor packages with third party PLC s due to open communication standards. Asset Management The integrated asset automatically generates asset information based on process hierarchy and feedback of intelligent devices asset information from mechanical equipment can easily be integrated manually. Fieldbus Foundation and PROFIBUS PA Intelligent Fieldbus devices in a mine are being managed through fully implemented Fieldbus communication standards and the powerful configuration and diagnostic tool SIMATIC (Process Device Manager). Stockyard area of a mine power control of a mine operation Highest availability and redundancy concept The SIMATIC PCS7 DCS controllers, scalable to highest performance needs (up to 4,000 IO counts per controller), offer extreme availablity based on reliable components and full redundancy on all automation levels adaptable to the specific process requirements. Advanced Process Control (APC) A free of charge APC library allows easy and cost-efficient implementations of APC applications with all the advantages of integrated solutions. Additional predefined APC packages for several process steps are available. IT security An integrated security concept specifically designed for industrial automation is a key element to ensure a reliable operation of the process. Remote Operation Center Remote operation to support and operate remotely a mine process helps to overcome a tight labor market with a centralized key team of experts and eases the operation of remote mines under extreme environmental conditions. Open system based on industrial standards An open system architecture provides industrial standards like OPC, Industrial WLAN, MODBUS, PROFINET, and web access as well as seamless integration of any equipment like drives, MCCs, CCTV, and IT systems. Training and simulation Our three stage concept of our operator training simulator starts with a simulation model for the engineering and FAT phase and leads to a training simulator system for the operator personnel during mine startup and the whole plant life cycle. Life cycle support services Our worldwide available service supports the complete plant life cycle from engineering to operations and enlarges the life cycle with sophisticated migrations concepts for fast and reliable migration of legacy and third party systems. 7
Industrial IT for minerals Siemens offers specialized industrial IT modules for managing tasks along the minerals supply chain for a complete vertical and horizontal integration. Siemens in the minerals industry With nearly 100 years of experience in the minerals industry Siemens is the perfect partner in optimizing your operational efficiency. Plan Mining Beneficiation Materials handling Load & haul Crush & screen Operations Flotation / separation Business planning Rail Build stockpile Contract to cash Load ship shipping Cross functions Finance & controlling EH & S Advanced process control applications Several specific APC applications based on the integrated APC library help you reach and maintain a constant product quality through optimization of production, throughput, and energy efficiency. Further APC applications for specific minerals process areas are under development. Geological model Strategic mine planning Medium / short term planning Drill & blast Blending optimization Fleet Production order Topographical road survey Beneficiation Production execution (day, shift etc.) Mass balance Reconciliation Operational compliance Enterprise Asset Management Supply Supply chain capacity planning Consumables Train Simulation Train control system Stockyard Transport order execution Blending 3D pile handling Berth Shipping order execution Shipment events logbook Quality Plant maintenance Business warehouse Intelligence suite Data historian OEE / DTM / KPI Master data (routes, materials, ) Statistical process control Energy LIMS ERP MES Control Gearless mill control The control system of the Siemens gearless mills is based on SIMATIC PCS7, too, and lets beneficiation areas also gain from seamlessly integrated process control solutions with increased efficiency during the whole life cycle of the gearless mill and reduced costs for training and spare parts. Seamless solutions for all plant levels available Functions and features Enterprise Resource Planning Based on the SAP Minerals best practice scenario we cover functions for business administration like Contract to cash, Costing, Enterprise Asset Management and many more. Production planning and Our production planning for minerals provides different planning levels as well as plant- and area-specific real-time, enabling an optimized company-wide supply chain capacity planning. Material and quality The material tracks the material flow and guarantees a full forward and backward genealogy with complete quality information. In combination with a laboratory information system this makes a quality routing and optimized blending possible leading to qualified ore ready to ship with the required certificate. Advanced 3D stockpile The advanced 3D stockpile add-on considerably eases quality planning and production of material mixes. The comprehensive material monitoring system tracks all quality and volume parameters in real-time. The result is a precise 3D visualization helping you track and plan material mixes with simple graphical links between stockpile areas. Manufacturing intelligence Contextualized KPIs, dashboards and analytical tools result in best-in-class decision support. Standard functionalities For specific MES tasks, software modules based on the latest industry standards (ISA S 95) are available covering everything from production order to energy, from HMI to reporting tools and from inventory to equipment handling. Flexible implementation Our modular approach uses standard technologies and permits a fast step-by-step implementation according to your needs. This sustainable, integrated out-of-the-box solution for minerals keeps up a clear product differentiation between ERP and MES functions. End-to-end services Our worldwide service organization delivers all-around services including IT operations. Energy Siemens your global industry partner for energy efficiency and environmental solutions provides an energy add-on in line with ISO 50001. It leads to a sustainable reduction of energy and environmental costs and has the ability to set effective and ambitious targets for the whole organization. Data collection, visualization at all corporate levels, targeting, forecasting, site and plant benchmarking, and load demand create added value for your daily business and are the basis for regulatory and political developments. 8 9
SIMINE automation and MES at a glance ERP MES Remote operation The glue for the entire mine process chain VPN-tunnel Firewall Plant operation Maintenance Engineering Process control & energy automation S7-300 Excavation Excavator 10 Shovel Draglines Plant asset Process optimization Web / remote access Trucks Trolley truck S7-300 conveyor Stacker / reclaimer Power distribution Transportation and bulk material handling Mine winders Process instrumentation Benefication Gearless mill drives Conventional mill drives Pump drives Refining agglomeration Flotation Electro winning Pelletizing 11