Mining is particularly sensitive to global economic swings

Owners and operators must adapt quickly to changing market conditions to stay competitive in this complex industry.

The wealth of South Africa’s mineral resources is renown worldwide and so is the country’s expertise for their extraction. But there’s more to this market than reputation. With globalisation, the MMM industry is one of the most competitive, relying as much on human labour as technological wizardry.

With resource prices fixed on the open market, the only way to increase turnover is to increase mining volumes and the only way to increase profitability is to reduce costs in the face of increasing raw material and energy costs.

In other words, the way to create shareholder value is to mine efficiently, improve product quality and to show employees that their demands are being viewed in the face of this global reality. This might mitigate industrial action and foster the spirit of competition needed to restore this industry to its former standard of excellence.

Challenges facing the Mining, Metals and Minerals industry

Health and safety

Intelligent information

Requires accurate real-time information on tap anywhere throughout the operation. This information needs to be available 100% of the time irrespective of power failures, server malfunctions or network failures.

  • System Platform
  • InTouch Access Anywhere
  • Historian
  • SmartGlance
  • Intelligence

Event resolution

Whether it’s a safety emergency or a production stoppage, the right personnel must know what to do without hesitation because this is not the time for trial and error. This makes human workflow mapping and management mandatory.

  • Skelta BPM Workflow

Minimising production costs

Process optimisation

In some instances, “doing it the way it’s always been done” may no longer be an option. Redesigning beneficiation processes, for example, can be difficult but at least one large SA company has done it and saved hundreds of millions.

  • Historian
  • Intelligence
  • Flow
  • MES/Performance

Improved capital plant ROI and reduced maintenance costs

Mining machinery such as refrigeration plants, conveyors, diggers, trucks, etc. is costly and its life needs to be extended as long as possible. This can be achieved through the rigorous, real-time monitoring of downtime and Overall Equipment Effectiveness (OEE) as well as effective maintenance based on reality rather than the calendar.

  • PRiSM
  • MES/Operations
  • IntelaTrac

Reduced energy costs

Keeping an eye on the meter is no longer good enough. Effective mine energy management involves tracking energy usage to batches and even shifts on a time basis in order to reduce energy usage during peak times but without affecting production.

  • Corporate Energy Management

Reduced downtime

This is helped through real-time and historical trending of plant items as well as precisely matching production with demand.

  • PRiSM
  • MES/Performance

Reduced industrial process control and industrial IT engineering costs

The mining industry has to perform under increasingly tight budgetary constraints but with fewer and fewer engineers. The proven way to cope with this scenario in a changing world is through the design, implementation, enforcement and maintenance of standards. Standards drastically cut engineering costs and lower the cost of ownership for the automation system as a whole.

  • System Platform
  • Historian
  • Intelligence
  • Flow

Preserving past investments and assets

Most mines have a collection of disparate automation systems as they evolved over time. Although these are valuable assets, what’s far more valuable is the engineering time and effort that was invested in their proper operation. What’s needed in these instances is a system that is designed with this very scenario in mind and that can make all these systems work in concert.

  • System Platform
  • InTouch
  • Historian
  • Device Integration Server

Customer Stories

Post Image
Customer Stories Mining, Metals and Minerals

Lonmin

Lonmin’s improved batch tracking and monitoring saves millions
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Lonmin

20% improvement in control system uptime at Lonmin’s Marikana Smelter with help from Wonderware
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Hulamin Limited

Hulamin saves money and increases customer satisfaction with help from Wonderware
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Sibanye Gold

Enterprise-wide power management gives Sibanye’s mines the control they need
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Exxaro Energy Mangement

People to make the difference between energy usage and waste at Exxaro’s Grootegeluk Mine
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Exxaro Resources Limited

Exxaro’s Grootegeluk mine opts for intelligent production reporting with help from Wonderware
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Exxaro Grootgeluk

Supervising the supervisory system at Exxaro’s Grootgeluk coal mine
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Exxaro GMEP

Doubling the world’s largest coal beneficiation complex
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Exxaro Coal (Pty) Ltd.

Not just information but an information modelling tool for Exxaro Coal
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

IAMGOLD Rosebel Gold Mines

Suriname gold mine benefits from SA knowhow and Wonderware solutions
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Lonmin PLC

Introducing situational awareness to Lonmin’s smelter operators
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Lonmin PLC

Guaranteed system availability is critical to safety at Lonmin’s smelter complex
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Richards Bay Coal Terminal

Large Terminal Control System upgrade at RBCT stabalises plant-critical operations
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Richards Bay Minerals

Richards Bay Minerals using new HMI situational awareness technology
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Richards Bay Coal Terminal

Large Terminal Control System upgrade at RBCT stabalises plant-critical operations
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Anglogold Ashanti (Geita Mine)

Enabling intelligent operations at a gold mine
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

ArcelorMittal end line inspection

ArcelorMittal’s Vereeniging Tubular Products plant remains a global player with help from Wonderware
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

ASSMANG Khumani Mine

“Proof of the pudding” in action at SA’s newest iron ore mine.
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

ASSMANG Black rock manganese beneficiation plant

ASSMANG’s Black Rock manganese beneficiation plant benefits from Iritron and Wonderware solutions.
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

ASSMANG Khumani Expansion Project

ASSMANG’s Khumani mine again turns to Iritron and Wonderware for its expansion project.
Learn More
Post Image
Customer Stories Mining, Metals and Minerals

Lonmin System Platform Upgrade

Major real-time SCADA upgrade at Lonmin - and who know it was happening?
Learn More

Helping Your Continuous Operation

Contact us to help you find a solution that suits your needs: