The significance of data management in mining

In today’s rapidly evolving technological landscape, the mining industry faces significant opportunities and challenges. Effective data management is crucial, but its application remains underutilised. This article explores how advanced data management and electrical solutions can transform mining operations, focusing on a detailed case study of the reclaimer reeler system at an iron-ore mine in Western Australia.

How can data management support mining?

Unlocking operational efficiency: Advanced data management enhances efficiency and productivity in mining operations. It provides the precision and insight necessary for informed decision-making and operational excellence. By leveraging data solutions, mining operations can achieve higher performance and reduce costs.

Streamlining operations: Mining processes require precise coordination for optimal efficiency. Effective data management facilitates real-time monitoring and analysis, enabling operators to quickly address bottlenecks and inefficiencies. This capability helps minimise downtime and operational costs.

Process optimisation: Modern data solutions are essential for optimising mining processes. They enable detailed analysis and real-time adjustments, improving operational efficiency. Integrating data from various sources streamlines workflows, reduces waste and improves resource allocation. This approach not only enhances production capabilities but also supports sustainable practices.

Case study: Bucket wheel reclaimer reeler system optimisation

Background

A Western Australian iron-ore mine found that its bucket wheel reclaimer — vital in mining operations for material handling — faced persistent challenges, particularly around the cable reeler, which provides electrical power to the machine. These issues led to delays and frequent maintenance due to flaws in the control scheme. The bucket wheel reclaimer is responsible for efficiently reclaiming and transporting bulk materials, a task critical to maintaining the flow of operations.

Challenges

• Control scheme flaws: The existing control system was prone to failures and inefficiencies, leading to operational delays.
• Maintenance issues: Frequent breakdowns and maintenance requirements were affecting productivity and increasing operational costs.

Solution implementation

1. Sensor and logging system installation: To address the control system flaws, sensors and logging systems were installed. These tools collected detailed data on system performance, providing insights into the root causes of the issues.
2. Data analysis: The collected data was analysed to identify specific flaws in the control scheme. For instance, one identified flaw was the control system’s inability to handle fluctuating load conditions, which caused frequent malfunctions.
3. Control program overhaul: A new control program was developed and implemented. An iba system was utilised for real-time monitoring and fine-tuning, allowing for dynamic adjustments based on real-time data. (The iba system consists of hardware and software components for acquiring, recording, analysing and processing measurement data. Due to its modular design and simple configuration, it can be adapted comfortably to various tasks and is scalable in size at any time.)

Results

The implementation of these solutions led to significant improvements:

• Enhanced reliability: The reclaimer reeler system saw a reduction in breakdowns and maintenance needs.
• Increased productivity: Operational delays were minimised, leading to higher efficiency.
• Proactive maintenance: The iba system’s real-time insights enabled proactive maintenance, further enhancing system performance.

Conclusion

As the mining industry advances, effective data management and electrical solutions become crucial for success. By adopting a data-driven approach and leveraging innovative technologies, mining operations can achieve new levels of efficiency, safety and sustainability. This case study of the bucket wheel reclaimer reeler system illustrates the transformative impact of targeted data management and control solutions.

Image credit: iStock.com/CUHRIG