1096 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
access, especially during the COVID pandemic. During
operation, if any issues arise, access to the machine is nec-
essary. It is impractical if access is weeks away. Often, the
access window itself is brief, allowing for only minor fixes.
Major issues require waiting for the next shutdown, poten-
tially 12–26 weeks away. Additionally, the lack of proper
documentation often makes it difficult to pinpoint the
exact root cause of issues or variations. These challenges
highlighted the need for a test rig development, where the
test environment can be monitored and controlled.
Building a test rig requires careful consideration of pur-
pose, technologies, budget, space, operation, and logistics.
To address these challenges, we have started developing a
small-scale test loop shown in Figure 2B. The test rig is
equipped with a Metso HM75 slurry pump, 15kW motor,
feed tank and various instruments that assists in developing
digital solution for pump condition monitoring and pro-
cess optimization. It aligns with our overall digital strategy
to create a pumping as a service offering. Nevertheless, even
this small test rig requires significant instrumentation for
data collection, highlighting the need for developing more
cost-competitive solutions. The market demands innova-
tive technologies that deliver insights without demanding
excessive upfront investment.
Sustainability Requirement
Sustainability is a key priority in the mining industry today
its importance continues to grow. In this pursuit, digita-
lization has emerged as a powerful enabler, empowering
miners to achieve savings in energy and water consumption
while minimizing their carbon footprint. At the heart of
this synergy lies data. Digital solutions generate and anal-
yse operational data, yielding valuable insights for identify-
ing inefficiencies, streamlining processes and making more
informed decisions that allow to strive for more sustainable
practices.
Pumps play a critical role in this sustainability journey.
We have written a paper for pumping sustainably, high-
lighting the need for a holistic approach and bring pumps
to the limelight instead of staying in the shadows of other
big machines (Varghese et al., 2022). In our research, we
have analysed over 43,000 pump sizing information from
1 January 2020 to 30 March 2022 and observed that most
commonly selected pumps are smaller (HM150, HM200
and HM100) and non-critical pumps that often lacks
proper monitoring. Additionally, only 17% of selections
for the most popular pump meet the sustainability range
shown in Figure 3A, which lies between the Best Efficiency
Line (BEL) and 80% of BEL (80% QBEL). Points below
80% QBEL indicate an oversized pump, while points
above BEL indicate an undersized pump. Likewise, analys-
ing over 33,000 pump motor sizing highlighted the most
common motor size was 11kW, 4-pole representing 6% of
total selections. Furthermore, only 50% of pump motor
sizing utilised Variable Frequency Drive (VFDs) despite
their significant energy savings. This data only reflects the
selection phase, which is based on empirical sizing rules,
and already shows significant oversizing—as noted only
17% falls in the sustainability range. Where does it operate
when eventually installed and running? Reinforcing that
proper instrumentation for pumps, is needed to identify
potential opportunities for reduced energy consumption
and reduced carbon footprint.
Implementation is Key
The digital revolution has created a buzz in our industry
with companies forming partnerships to develop cutting-
edge solutions. In our industry, it is seldom someone wants
to take the risk to be the first to try new tools. Customers
commonly ask for references and trial test results before
committing to trying themselves. However, in the case of
digital, it is remarkable to see customer’s openness to trying
new digital tools, technologies, or solutions compared to
traditional equipment. We believe the shift is from the per-
ceived low risk, as digital is seen as “add-ons” that enhance
existing processes without jeopardizing core operations. A
malfunctioning sensor installed for data collection, and
which is not used for automation or control, is of less risk
compared to halted production line due to equipment fail-
ure. Consequently, we have observed a faster approval pro-
cess for digital trials. However, the implementation stage
has emerged as a major hurdle. The complexities of IT
integration, reluctance in data sharing, data security, infra-
structure needs, and lengthy set-up times lower enthusiasm
and stall progress. This is an exciting opportunity where
we recommend industry players and researchers to collabo-
rate on developing standardised methods for streamlining
implementation. Additionally, overcoming this bottleneck
can also pave the way for future sustainability and bench-
marking initiatives described by Pirouz et al. (2017). Our
experience is further evaluated in Figure 3B offering a visual
snapshot of findings. The term “experience” in this context
encompasses (i) ease of interaction with client representa-
tives, (ii) access to compatibility of cybersecurity systems,
(iii) lack of overlapping guidelines between the supplier and
the customer infrastructure systems and (iv) jargon/com-
munication used by different parties. While it is difficult to
define specific measures of “experience” at market infancy,
we reflect on lessons learned and illustrate the possible areas
of improvement in Figure 3B.
access, especially during the COVID pandemic. During
operation, if any issues arise, access to the machine is nec-
essary. It is impractical if access is weeks away. Often, the
access window itself is brief, allowing for only minor fixes.
Major issues require waiting for the next shutdown, poten-
tially 12–26 weeks away. Additionally, the lack of proper
documentation often makes it difficult to pinpoint the
exact root cause of issues or variations. These challenges
highlighted the need for a test rig development, where the
test environment can be monitored and controlled.
Building a test rig requires careful consideration of pur-
pose, technologies, budget, space, operation, and logistics.
To address these challenges, we have started developing a
small-scale test loop shown in Figure 2B. The test rig is
equipped with a Metso HM75 slurry pump, 15kW motor,
feed tank and various instruments that assists in developing
digital solution for pump condition monitoring and pro-
cess optimization. It aligns with our overall digital strategy
to create a pumping as a service offering. Nevertheless, even
this small test rig requires significant instrumentation for
data collection, highlighting the need for developing more
cost-competitive solutions. The market demands innova-
tive technologies that deliver insights without demanding
excessive upfront investment.
Sustainability Requirement
Sustainability is a key priority in the mining industry today
its importance continues to grow. In this pursuit, digita-
lization has emerged as a powerful enabler, empowering
miners to achieve savings in energy and water consumption
while minimizing their carbon footprint. At the heart of
this synergy lies data. Digital solutions generate and anal-
yse operational data, yielding valuable insights for identify-
ing inefficiencies, streamlining processes and making more
informed decisions that allow to strive for more sustainable
practices.
Pumps play a critical role in this sustainability journey.
We have written a paper for pumping sustainably, high-
lighting the need for a holistic approach and bring pumps
to the limelight instead of staying in the shadows of other
big machines (Varghese et al., 2022). In our research, we
have analysed over 43,000 pump sizing information from
1 January 2020 to 30 March 2022 and observed that most
commonly selected pumps are smaller (HM150, HM200
and HM100) and non-critical pumps that often lacks
proper monitoring. Additionally, only 17% of selections
for the most popular pump meet the sustainability range
shown in Figure 3A, which lies between the Best Efficiency
Line (BEL) and 80% of BEL (80% QBEL). Points below
80% QBEL indicate an oversized pump, while points
above BEL indicate an undersized pump. Likewise, analys-
ing over 33,000 pump motor sizing highlighted the most
common motor size was 11kW, 4-pole representing 6% of
total selections. Furthermore, only 50% of pump motor
sizing utilised Variable Frequency Drive (VFDs) despite
their significant energy savings. This data only reflects the
selection phase, which is based on empirical sizing rules,
and already shows significant oversizing—as noted only
17% falls in the sustainability range. Where does it operate
when eventually installed and running? Reinforcing that
proper instrumentation for pumps, is needed to identify
potential opportunities for reduced energy consumption
and reduced carbon footprint.
Implementation is Key
The digital revolution has created a buzz in our industry
with companies forming partnerships to develop cutting-
edge solutions. In our industry, it is seldom someone wants
to take the risk to be the first to try new tools. Customers
commonly ask for references and trial test results before
committing to trying themselves. However, in the case of
digital, it is remarkable to see customer’s openness to trying
new digital tools, technologies, or solutions compared to
traditional equipment. We believe the shift is from the per-
ceived low risk, as digital is seen as “add-ons” that enhance
existing processes without jeopardizing core operations. A
malfunctioning sensor installed for data collection, and
which is not used for automation or control, is of less risk
compared to halted production line due to equipment fail-
ure. Consequently, we have observed a faster approval pro-
cess for digital trials. However, the implementation stage
has emerged as a major hurdle. The complexities of IT
integration, reluctance in data sharing, data security, infra-
structure needs, and lengthy set-up times lower enthusiasm
and stall progress. This is an exciting opportunity where
we recommend industry players and researchers to collabo-
rate on developing standardised methods for streamlining
implementation. Additionally, overcoming this bottleneck
can also pave the way for future sustainability and bench-
marking initiatives described by Pirouz et al. (2017). Our
experience is further evaluated in Figure 3B offering a visual
snapshot of findings. The term “experience” in this context
encompasses (i) ease of interaction with client representa-
tives, (ii) access to compatibility of cybersecurity systems,
(iii) lack of overlapping guidelines between the supplier and
the customer infrastructure systems and (iv) jargon/com-
munication used by different parties. While it is difficult to
define specific measures of “experience” at market infancy,
we reflect on lessons learned and illustrate the possible areas
of improvement in Figure 3B.