This white paper examines the trends, challenges and opportunities associated with underground mining in the race to net zero and a discussion around hoisting as an available zero emissions solution. Significantly, it includes the case study of the BHP Group Limited new production hoist at Prominent Hill in South Australia – an example of how hoisting can increase the annual underground mining rate, extend a mine’s life, lower operating costs, and increase safety in addition to reducing emissions.
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2023 ABB in Australia ABB supporting Australian Mining since 1906
Committed to unlocking value
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Pioneering technology leadership
With a 130-year history of innovation, ABB today is writing the future of industrial digitalisation and driving the Energy and Fourth Industrial Revolutions within the mining and resource sector.
World leaders in power and automation
Every day, our inventions and innovations drive progress and productivity for energy, industries, transport and infrastructure, and help make a greener, more efficient world.
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70 million digitally enabled devices; 70,000 digital control systems; 6,000 enterprise-level software solutions The world's first gearless mill drive, which we delivered over 50 years ago recently we commissioned the world's most powerful gearless conveyor drive, improving performance significantly and reducing CO2 emissions enormously.
Decades of experience of process automation
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Our decades of understanding and insights across more than 20 industries means we know the scientific, engineering and business reasons that underpin decisions.
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Deep sector knowledge
Let’s write the future
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August 2, 2023
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ABB in Australia
Total workforce 670
Orders Dec 2022 $646 MAUD
Sales offices and service centres across Australia supporting all ABB systems and products
Victoria :
Queensland :
• Notting Hill
• Fortitude Valley • Eagle Farm • Darra • Tingalpa
WA :
• Perth
NSW :
• Moorebank • Singleton
Moorebank, Sydney
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August 2, 2023
© Copyright 2020 ABB. All rights reserved.
— ABB Safety Partner of choice to keep your operations safe
2020
2021
2022
LTIFR
0.232
0.00
0.028
TRIFR
0.697
0.129
0.168
Series Injuries (Sis)
1
0
1
AUABB HSE&S Tender Information | August 2023 (click here to view)
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August 2, 2023
© Copyright 2020 ABB. All rights reserved.
Strong enterpriseculture
Our Code of Conduct is the foundation
We arecommittedto fosteringa culturewhereintegrityis woven into everything we do and is at the core of our governance, along with transparency. Integrity is a prerequisite for a world- class business and our reputation as a trusted and reliable business partner.
Björn Rosengren Chief Executive Officer
• The ABB Code of Conduct expresses our strong collective and individual commitment to integrity • It applies globally to allof ABB’s employees, managers, officers, and directors , including ABB’s wholly-owned affiliates and subsidiaries, and employees ofjointventureor otherentitiesthathavemajority ownership interest or exercise effectivecontrol • It empowers employees to speakup when they see any violations of the Code without fear of retaliation Where to findthe ABB Code of Conduct:QR Code and a linkto view and download the PDF version are available on the following page: https://global.abb/group/en/about/integrity/standards/abb-code- of- conduct
How we drive strong enterprise culture Our values are the cornerstone of our culture and shape everything we do
Courage
Care
Curiosity
Collaboration
AtABB,we:
AtABB,we:
AtABB,we:
AtABB,we:
• Take action and manage consequences
• Take care of our customers, our peopleand the environment
• Believethere is always abetterway
• Believe smart people collaborate
• Lead withtechnologies and innovations
• Buildon each other’s strengths and success
• Speakup and ask forhelp
• Respect and value differences
• Takecalculatedrisks to create success
• Dowhat is right and act with integrity
• Learn fromfailures and successes
• Partner withour customers
Integrity
Couragethrough empowerment and accountability
Care through respect and governance
Curiosity through awareness andcontinuous improvement
Collaboration through transparency
Proudly in Australia since 1906
1906 UK company George Kent Ltd commences production of domestic water meters in Perth, Western Australia
BBC Group acquires controlling interestin George Kent Group, becomes Kent Instruments 1988 ABB Group formed following the global merger between ASEA and Brown Boveri 1998 ABB acquires Elsag Bailey Process Automation to become the market leader in the global automation market 1999 ABB divests its nuclear power, power generation and rail businesses focusing on developing its market strengths in alternative energy
Xstrata Copper Ernest Henry mine: complete shaft hoisting system
2001 Creation of single ABB company: ABB Australia Pty Limited 2002 System 800xA first deployed in Australia at Queensland Nickel to integrate multiple legacy systems 2006 Introduction of local business unit for Mining in Australia
2014 ABB completes acquisition of Power-One 2017 BHP Billiton Olympic Dam Clark shaft hoist system 2020 Newmont Tanami Expansion 2 Project complete friction and double drum hoist system ARC Advisory Group confirmed that ABB remains #1 DCS market leader for 21 st year running
2011 ABB acquires Mincom in Australia to expand Enterprise Software Business Xstata Zinc George Fisher Mine: complete shaft hoisting system (L72) ABB acquires Powercorp in Australia to broaden renewable power automation and control systems offering for wind and solar energy such a microgrids 2012 AAMC Grosvenor Coal Project complete ECIS solution 2012 Wiggins Island Coal Export Terminal Project complete ECIS solution
1934
ASEA Electric incorporated In NSW
1960 Brown Boveri (BBC) is
incorporated in Australia, commencing with a small factory at Artarmon, Sydney
Vale Goro Nickel largest 800xA system globally
2008 Koniambo Nickel: largest multi 800xA system globally
1970 ASEA begins manufacturing high voltage capacitor banks in Lilydale, Victoria 1974 BBC acquires major switchboard manufacturer based in Liverpool, NSW
2021 ABB launches ABB Ability ™ eMine
2010 ABB acquires Baldor Electric Company to become a global leader in industrial motion
Introduction of System 800xA DCS
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August 2, 2023
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Indigenous reconciliation & engagement
ABB takes action to improve Aboriginal and Torres Strait Islander education outcomes. • ABB supports the Indigenous Literacy foundation where we recognise the critical importance of the work that they do.
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August 2, 2023
© Copyright 2020 ABB. All rights reserved.
Recognised on Australian Financial Review’s most innovative
In 2021, ABB was included on the Australian Financial Review BOSS Most Innovative Companies list for our groundbreaking collaboration with global gold miner Gold Fields to implement one of the world’s most digitally enabled underground mines. Gold Fields aims to be one of the most digitally connected, innovative miners in the world, and chose its Granny Smith. The Granny Smith mine in Western Australia as the flagship for transforming operations. Using real- time data, ABB’s operations and fleet management systems can maximize deployment of equipment and orchestrate the workforce to progress more seamlessly from task to task, adapting to events as they occur.
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August 2, 2023
Major Australian customers across all sectors
Bechtel
CPP
Jacobs
Laing O’Rourke
Worley Parsons
EPC
Calibre Projects
Downer
John Holland
Lendlease
Worsley
CPB Contractors
Fluor
KBR
Lycopodium
Arnotts/Campbells
Coca Cola
George Weston Foods Goodman Fielder
Nestle
Food and beverage
Cadbury
Manufacturing
Beovista
Electrolux
Wilson Transformer Co
Anglo American Coal
Glencore
Newcrest
Rio Tinto
Prony Resources
Minerals and Mining
BHP Group
Gold Fields
Queensland Alumina Roy Hill Mine
Worsley
Fortescue Metals Group
Arrow Energy
BP
ConocoPhillips
Origin Energy
Shell Australia
Oil and Gas
BG Group
Caltex
ExxonMobil
Santos
Woodside
Pulp and Paper
Kimberly-Clark
Opal
Visy
Norske Skog
QTP
Sorbent
Huhtamaki
Encore
Aurizon
MTM
Queensland Rail
Yarra Trams
Rail
GoldLinQ
PTA
Transport for NSW
ActweAGL
Energex
Jemena
Transend
Water Corporation
Utilities
Ausnet Services
Ergon Energy
PowerCor/CitiPower
Transgrid
Western Power
Ausgrid
Essential Energy
Powerlink
Synergy
UED
Endeavor Energy
Horizon Power
SA Power Networks
Intergen
Gemcell
Middy’s
MM Electrical
Powerline Supplies
Rexel
Wholesale
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August 2, 2023
L&H
— Mining & Minerals sector Project highlights
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ABB’s Highest Payload Production Hoist
Prominent Hill, BHP
• BHP (previously OZ Minerals’) gold, silver, and copper mine began operations in 2009 as an open-pit mine. Now an underground mine producing over 4.5 Mt/y via a trucking operation, hoisting will provide access to resources outside the current trucking plan that would have been uneconomical from around 2033.
Customer needs
• The contract will help to ensure efficient processing performance and a long service life as part of an ongoing $400 million expansion at the South Australian mine. • The hoist, which will be designed and supplied by ABB, has a capacity of 39,400 kg and the strongest drivetrain that ABB has ever installed in Australia. ABB specialists will also supervise installation and commissioning. These products are certified by an independent global functional safety certifying body, and strictly developed in accordance with the International “Safety of Machinery” standard IEC62061. • The mine hoist will bring the highest level of personnel and equipment safety with the first fully SIL 3 certified solution for hoists. • The mine hoist will use the ABB Ability ™ Safety Plus suite of mine hoist safety products includes Safety Plus Hoist Monitor (SPHM), Safety Plus Hoist Protector (SPHP), and Safety Plus Brake System (SPBS) including Safety Brake Hydraulics (SBH). •
ABB solution
Customer value
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August 2, 2023
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Setting new standards for deep underground mining
Tanami Expansion 2 Project, Newmont
• Newmont is the world’s largest gold mining company and explores and produces copper, silver, zinc and lead. • The customer required mine hoist technology for its Tanami Expansion 2 project (TE2) to help boost production by accessing the ore at greater depths.
Customer needs
• ABB will design, supply, install and provide long-term service and support of the mine hoist mechanical and electrical systems, even in remote locations like the Tanami Desert. • ABB will deliver two complete mine hoist systems, a double drum personnel-riding hoist and a friction hoist, to support the extension of mining operations at Tanami.
ABB solution
Customer value
• ABB’s state -of-the-art control and drive technology, experienced project management and advanced service tools will enable the customer to increase the output of the mine, facilitate deeper mining, improve overall safety and help lower operational costs
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August 2, 2023
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ABB’s first digital mine solution in Australia
Goldfields, Granny Smith Mine
• Granny Smith Mine (GSM) is an underground gold mining operation located 740km northeast of Perth, Western Australia. • Goldfields was seeking a digital solution to streamline their data capture processes which is currently manually done, and to utilize this data to create insights that will drive improved operational productivity. • ABB will develop Fleet Management System (FMS), an operations management software platform solution, which will replicate the existing control room system capability. • The FMS will be the primary system for managing locations, equipment and operators underground. This will improve information flow and increase levels of visibility within our mining operations and improve utilization of the mobile fleet.
Customer needs
ABB solution
Customer value
• Through innovative solutions like FMS that improve information flow and visibility across mining operations, we help enable operators to react in real time to any unplanned events and assist in their scheduling and planning, leading to operational excellence
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August 2, 2023
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Delivering industry-leading energy efficiency at new iron-ore mine
FMG, Iron Bridge Magnetite
• Located in the Pilbara region of Western Australia, the mine is expected to produce 22 wet million tonnes per annum of high grade, magnetite concentrate used for steel production. • FMG required a cost-effective energy efficient variable speed drive solution.
Customer needs
• ABB will provide water-cooled variable speed drives and high voltage induction motors that will deliver industry-leading energy efficiency at new iron-ore mine developed by Fortescue Metals Group
ABB solution
• ABB’s water -cooled drives require less energy and deliver less heat, making it easier to maintain the required 30° C temperature in the eight switch rooms on site. • ABB high voltage induction motors will be used to power high pressure grinding rolls, grinding mills and baghouse fans used to separate the ore from the dust. With a compact footprint that weighs 40% less, the motors are energy efficient, save space and require less structural foundation.
Customer value
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August 2, 2023
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Improving reliability and minimizing risk of critical assets
Perilya Broken Hill
• Complete electrical and automation upgrade to achieve provisions for a control and safety system that is compliant with the current NSW requirements for mine winders
Customer needs
• Designed, engineered and supplied full electrical solution utilising:
➢ ABB Ability ™ Asset Health Centre control solution;
➢ ABB’s SIL 3 Certified Safety Hoist Monitor (SHM);
ABB solution
➢ engineered hoist protection system including shaft boxes, drivers desk, DCS800 drive and motor control centres. • Electrical installation and commissioning
• Optimise the overall performance, reliability, energy efficiency and operational flexibility of the winders over its lifetime • Pre-engineered solution, faster commissioning, repeatability, commonality of equipment and parts, overall maintenance reduction • Compliance to NSW mine winder requirements and future proof amendments • Back-to-back winder upgrade to reduce overall project cost using common design aspects
Customer value
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August 2, 2023
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Delivering real-time enterprise visibility
Atlas Iron
• Production data consisting of stockpile location, tonnes and grades from pit to port was being tracked using complex Excel workbooks • Draining already lean technical resources and preventing effective decision making across the entire production value chain • Atlas Iron needed a quick implementation with minimal associated risks
Customer needs
•
MineMarket:
ABB solution
➢ real-time enterprise visibility across the entire product and logistics process, from ore extraction to product delivery, and through to the fulfilment of contracts
➢ track of ore, concentrate, and product inventory across the entire supply chain
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Estimated saving 2-3 hrs per day
• MineMarket enables Atlas Iron to make clear and informed business decisions on today and into the long term future
Customer value
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August 2, 2023
Long term service agreement Prony Resources, New Caledonia
• In 2010, ABB delivered a site-wide 800xA control system and continued to support with expansion projects and a service agreement. • In 2021/2022, ABB delivered a controls upgrade for Boiler #4 and the customer expressed interest in a nearly identical upgrade to Boiler #5. • 800xA control system integration for new boiler #5. Includes functional safety design. Supply of hardware in panels and associated engineering, programming and site commissioning.
Opportunity
Description
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New control system
ABB solution
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Hardware and licences
• Supply of safety engineering, programming and commissioning
• Service excellence and experience with Boiler #4 • We collaborated transparently with the customer to demonstrate the need for engineering was justified due to detailed safety design and ABB expertise of the site control system and even offered at time and materials for opportunity for engineering costs to come down if ABB overestimated.
Why ABB?
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August 2, 2023
Reliable and efficient operation OK Tedi Mining, Papa New Guinea
Opportunity
• In 2020 MIPAC and ABB completed an upgrade at OTML’s Kiunga Plant. • Following the successful execution of this project, OTML have begun Phase 2 of their Process Asset Replacement Project
• Ensure reliable and efficient operation of plant with predictable and cost efficient service and maintenance activities
Description
• New control system components, software and architecture consultancy services
ABB solution
• OTML rely on ABB and MIPAC as their preferred partner for the DCS on site in PNG. • This is an ongoing relationship where we provide onsite and remote support, training, system evolution, software support etc.
Why ABB?
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August 2, 2023
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Newcrest, Cadia East Underground Expansion
• Complete electrical and automation system for six underground inclined conveyors with a total length 8.8km, total lift of 1.4km and an installed power of 26.7MW
Customer needs
• Designed, engineered and supplied full Electrical and Automation solution consisting of:
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7 x 33kV Ring Main Units
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5 x 8MVA Transformers
ABB solution
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10 x Transportable Switchrooms
➢ 5 x Water Cooled ACS 6000 Multidrives with Mining Conveyor Control Program
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5 x Water Cooled Brake Resistors
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5 x Low Voltage MCCs and UPS
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10 x Water Chillers
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19 x 3.3kV Induction Motors
• State-of-the-art conveyor control system that optimises the overall performance, reliability, energy efficiency and operational flexibility of the conveyor system over its lifetime.
Customer value
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August 2, 2023
Karara Mining, Geraldton
• Analysis of the Drives Preventive Maintenance Schedule and considering the installation date of the drives and upgrades required. • During the negotiation stage, an opportunity for a spare TX for the HPGR was found because of the analysis of the spares done. • 4 x ACS1000 Drives at Karara Mining were installed in 2013. According to the PM schedule for those Drives, they are due for a 10 Years Preventive Maintenance in 2023. • In 2017,we were informed that the Main Board INT2 of these drives were at the end of their lifecycle, therefore, an upgrade for the control board was available .
Opportunity
Description
• Conduct preventative maintenance and firmware upgrades on ABB ACS1000 drive systems on the High-Pressure Grinding Rolls at Karara Mine, plus 1xHPGR Spare Transformer.
ABB solution
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August 2, 2023
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