MES Implementation at Impala Platinum

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MES Implementation at Impala Platinum

• Merinda Westcott

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Impala Platinum
Impala Platinum
Impala Refineries
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Company History

• 1924 Hans Merensky discovered platinum in ore
  sample
• 1925 Prospecting shafts were sunk in area
• 1967 Impala Platinum Holdings LTD was
  established
• 1969 Production started at 100 000 ounces
  platinum per year

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Impala Platinum Information

• Operations consist of
• Mining Rustenburg
• Mineral Processes Rustenburg
• Base metals refinery - Johannesburg
• Precious metals refinery Johannesburg
• Currently employs 28 000 people
• Second largest platinum producer in the world
• 13 Operational shafts producing 16.5 million tons
  per year
• Implats production 1.9 million ounces of platinum
  per year

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Process Flow Mineral Processes
Concentrator
Ore from Shafts
Tails to Tailings Dam
Milling
Flotation
Smelter
Off Gas Treatment
Dryers
Smelting
Converting
Final Product to Refinery
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Milling
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Process Flow Mineral Processes
Concentrator
Ore from Shafts
Tails to Tailings Dam
Milling
Flotation
Smelter
Off Gas Treatment
Dryers
Smelting
Converting
Final Product to Refinery
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Flotation
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Process Flow Mineral Processes
Concentrator
Ore from Shafts
Tails to Tailings Dam
Milling
Flotation
Smelter
Off Gas Treatment
Dryers
Smelting
Converting
Final Product to Refinery
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Dryers
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Process Flow Mineral Processes
Concentrator
Ore from Shafts
Tails to Tailings Dam
Milling
Flotation
Smelter
Off Gas Treatment
Dryers
Smelting
Converting
Final Product to Refinery
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Smelting
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Process Flow Mineral Processes
Concentrator
Ore from Shafts
Tails to Tailings Dam
Milling
Flotation
Smelter
Off Gas Treatment
Dryers
Smelting
Converting
Final Product to Refinery
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Converting
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Process Flow Mineral Processes
Concentrator
Ore from Shafts
Tails to Tailings Dam
Milling
Flotation
Smelter
Off Gas Treatment
Dryers
Smelting
Converting
Final Product to Refinery
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Gas Treatment
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Historical Data Management

• Multiple systems and reports
• Manual entry of data available electronically
• Duplication of data in multiple excel
  spreadsheets
• Excel used for all performance calculations and
  reporting
• Data inaccessible and insecure
• No audit trail

Management Report
Performance Calculations
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MES Solution

• Central repository for all data
• Calculations performed in centrally controlled
  environment
• Interface to all data sources
• All reporting from one data source
• One user interface to access data
• Interface to SAP

Reports
SAP
Trends
Graphics
Performance Calculations
Data Historian
Plant Data
Rail Transport
Manual Data
Lab Data
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Project Detail

• Interfacing
• Historian
• Performance calculations
• Downtime monitoring application
• User interface

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Interfacing Plant Control Systems

• Three CIMIO servers used to retrieve plant data
• Use Aspentechs CIMIO for OPC interface
• 44 841 tags from 39 PLCs at 10 sec interval
• Initially used remote OPC servers
• TopServer OPC Server installed on CIMIO servers
• Store Forward implemented on CIMIO servers

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Interfacing Rail Transport

• Manages downloading and recording of ore
  movements at Mineral Processes
• Captures transactional data in Access Database
• Uses ODBC connection for data transfer

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Interfacing -LIMS

• Plant samples analysed for PGM content
• Create Staging Table in LIMS
• ODBC connection to staging table
• Use SQL and mapping table to insert values into
  records

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Interfacing - Excel

• Download business plans

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Interfacing - SAP

• Use Operations Manager Integration Infrastructure
  (OMII)
• Maintenance management
• Notifications of equipment operating outside
  limits
• Custom RFC
• Running hours of critical equipment
• Standard RFC MEASUREM_DOCUM_RFC_SINGLE_001
• Monthly key performance data
• Uploading of monthly plant performance data to
  SAP
• Standard RFC ZPM_ACTIVITY_CREATE

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Business Works Flow
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Project Detail

• Interfacing
• Historian

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Historian

• Replace existing 3 Wonderware historians with one
  IP21 historian
• Historian includes plant data as well as results
  from performance calculations
• Number of repositories 9
• On-line data stored for 2 years

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Project Detail

• Interfacing
• Historian
• Performance calculations

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Performance Calculations

• Replace daily performance calculations done in
  excel
• Total Calculations 927
• System requirements
• Easy management of calculation formulae
• Ability to execute calculations in pre-defined
  order
• Automated scheduling of calculations
• Ability to use conditional statement
• Ability to recalculate
• Project implementation
• Use Aspencalc as calculation engine
• Design database structure and SQL to satisfy
  requirements

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Project Detail

• Interfacing
• Historian
• Performance calculations
• Downtime monitoring application

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Project Detail

• Interfacing
• Historian
• Performance calculations
• Downtime monitoring application
• User interface

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User Interface

• Users Operations managers, plant engineers,
  metallurgists,
• plant superintendents, engineering foreman
• Interface requirements
• Production reporting
• Downtime reporting
• Manual data entry
• Performance analysis of plant equipment
• Performance analysis of processes
• Fault finding and troubleshooting
• Web 21 used as primary interface for MES users
• Process Explorer used for trending

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Web 21 - Reporting
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Web 21 Data Entry
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Web 21 - Graphics
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Web 21 - Graphics
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Trending
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Conclusion and Benefits

• Project completed in 6 months and within budget
• Few problems experienced during testing phase
• Currently being rolled out to users
• Eliminate multiple version of information
• Data more easily accessible to users
• More secure environment for information
  management

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Way Forward

• Expand performance calculations to weekly and
  monthly reports
• Expand available reports
• Integrate with refineries MES
• Continual improvement and development

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• THANK YOU