asset optimization for - mppiglobal

LOCATION Africa CATEGORY Mining COMMODITY Copper YEAR 2013 The Company A mid-tier copper mining company in Australia with copper assets globally. The company produces 200,000 tonnes of copper but is aiming for continued copper production growth in the near future. The Challenge One site in Africa struggled to deliver planned production output due to an under-performing copper operation that was constrained by the electrowinning (EW) plant. EW was consistently below target in most measured variables such as current efficiency, current density, supplied amps, copper supplied, plated and stripped. With limited information available, production improvement was at a standstill. The Solution Production OEE is an integrated solution with sophisticated built-in logic developed to deliver insight on production restrictions. The standard program incorporates a combination of integrated Information Technology and tools for Continuous Improvement. The system has similarities to a standard manufacturing OEE model but is applied as a production centric model across the value chain making it different, and infinitely more powerful at identifying and prioritising losses across an operation and for any asset. Implementation The Asset Optimization project involved a brief period of discovery to establish a functional specification. Based on the functional specification a specific Production OEE model for electrowinning was developed and implemented. The model developed included an automatic reporting system to highlight the biggest production losses and opportunities for improvement. This information allowed us to help the client create projects and act on specific issues that restricted overall production. This particular deployment was done as part of a program spanning multiple countries and operations but is easily implemented as a one-off as required. Results Increased data availability, visibility and execution of continuous improvement projects increased production in electrowinning on average by 25%. Improvements realised were: • Less power interruptions and faster ramp up of power to EW after trips and blackouts. • Less shorts through improved operational and crane handling practices. • Solved critical reliability issues in major electrical and mechanical equipment. • Stabilised processing parameters overall in the plant. The Asset Optimization project delivered an additional 14,000 tonnes of copper on an annualised basis, representing approximately an additional AUS$80 million in revenue. Tel: +61 7 3245 2500 [email protected] ASSET OPTIMIZATION FOR COPPER ELECTROWINNING CASE STUDY Jan 13 Feb 13 CY 12 avg March 13 April 13 May 13 June 13 90 85 80 75 70 65 60 55 50 45 40 80 84 83 74 63 67 52 OEE % Production OEE in Copper Electrowinning www.mppiglobal.com

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Page 1: ASSET OPTIMIZATION FOR - MPPIglobal

LOCATIONAfrica

CATEGORYMining

COMMODITYCopper

YEAR2013

The CompanyA mid-tier copper mining company in Australia with copper assets globally. The company produces 200,000 tonnes of copper but is aiming for continued copper production growth in the near future.

The ChallengeOne site in Africa struggled to deliver planned production output due to an under-performing copper operation that was constrained by the electrowinning (EW) plant. EW was consistently below target in most measured variables such as current efficiency, current density, supplied amps, copper supplied, plated and stripped. With limited information available, production improvement was at a standstill.

The SolutionProduction OEE is an integrated solution with sophisticated built-in logic developed to deliver insight on production restrictions. The standard program incorporates a combination of integrated Information Technology and tools for Continuous Improvement.

The system has similarities to a standard manufacturing OEE model but is applied as a production centric model across the value chain making it different, and infinitely more powerful at identifying and prioritising losses across an operation and for any asset.

ImplementationThe Asset Optimization project involved a brief period of discovery to establish a functional specification. Based on the functional specification a specific Production OEE model for electrowinning was developed and implemented. The model developed included an automatic reporting system to highlight the biggest production losses and opportunities for

improvement. This information allowed us to help the client create projects and act on specific issues that restricted overall production.

This particular deployment was done as part of a program spanning multiple countries and operations but is easily implemented as a one-off as required.

ResultsIncreased data availability, visibility and execution of continuous improvement projects increased production in electrowinning on average by 25%.

Improvements realised were:

• Less power interruptions and faster ramp up of power to EW after trips and blackouts.

• Less shorts through improved operational and crane handling practices.

• Solved critical reliability issues in major electrical and mechanical equipment.

• Stabilised processing parameters overall in the plant.

The Asset Optimization project delivered an additional 14,000 tonnes of copper on an annualised basis, representing approximately an additional AUS$80 million in revenue.

Tel: +61 7 3245 [email protected]

ASSET OPTIMIZATION FOR COPPER ELECTROWINNING CASE STUDY

Jan 13 Feb 13CY 12 avg March 13 April 13 May 13 June 13