AspenTech is providing intelligent digital solutions to the mining industry, helping reduce downtime and emissions while maximising asset performance.
Mobile and fixed equipment plant maintenance is one of the costliest parts of a mining operation. This stems from the fact that site operators typically rely on preventive maintenance schedules designed by the original equipment manufacturer.
But this system is too rigid to depend on, and can fail to account for variations in the use of equipment, different working environments and the effects of extreme weather. It’s the equivalent of ignoring the warning light in a car because it’s still got three months until the next service.
There is a better way of doing things, and it’s called prescriptive maintenance. AspenTech’s Aspen Mtell solution offers the mining industry exactly that.
Aspen Mtell is a predictive and prescriptive maintenance solution that uses machine learning to monitor equipment in real-time for imminent and future failures.
“Companies are facing increasing pressure to reduce their carbon footprint and improve operational efficiency in order to meet global climate targets,” senior industry marketing consultant for AspenTech, Brandon Richardson, told Australian Mining. “To deal with these challenges, many companies are turning to digitalisation solutions.
“AspenTech offers advanced digitalisation solutions specifically designed to assist companies in the mining industry to achieve their sustainability goals and improve operational efficiency, while also minimising costly environmental and safety risks.
“AspenTech’s asset performance management solutions provide a comprehensive suite of tools, including Aspen Mtell, to monitor and optimise performance of mining assets.”
By monitoring machine performance round-the-clock, the Mtell software can recognise patterns indicative of degradation and impending failure. These early warnings give site operators the chance to plan maintenance weeks – and sometimes months – ahead, rather than reactively working through equipment failures at the expense of time and money.
“The high costs associated with maintenance, repairs, and downtime can be a significant burden for mining companies,” Richardson said.
“AspenTech helps address these challenges by providing predictive maintenance solutions that can reduce downtime and maintenance costs.”
Aspen Mtell has been tried and tested in the field, and the results speak for themselves.
“A particular mining client was having difficulty predicting when maintenance was required on their trucks, resulting in frequent breakdowns and increased maintenance costs,” Richardson said.
“By implementing Aspen Mtell, the company was able to analyse sensor data from the trucks and develop predictive models called agents that could accurately forecast maintenance needs.
“This allowed the company to proactively schedule maintenance, reducing unplanned downtime and improving overall equipment reliability.”
Aspen Mtell is also making operations safer. In one instance, the software flagged a failure in a customer’s oil heater.
“In those types of industrial machines, a failure would have meant hot oil vaporising cold water, which would have caused a rapid steam explosion,” Richardson said.
“A failure would have had catastrophic safety implications, but thanks to Aspen Mtell, the site operator was able to take pre-emptive action and avoid an accident.”
Aspen Mtell pairs well with another AspenTech solution, known as advanced process control (APC). APC provides real-time control and optimisation of equipment, helping mining companies make their operations run as efficiently as possible.
“APC enables mining companies to optimise their production processes and reduce energy consumption,” Richardson said. “AspenTech APM and APC solutions help mining companies to make data-driven decisions that improve process efficiency, optimise production, and reduce environmental impact.
“The integration of AspenTech APM and APC solutions ensures that mining companies can achieve their sustainability objectives while remaining competitive in an uncertain economic environment.”
Energy efficiency and safety play a huge role in achieving environmental, social and governance (ESG) targets, meaning solutions like Aspen Mtell are vital for staying competitive in an evolving mining market.
And ESG targets are much more than just a peripheral consideration.
There is tangible value for mining companies in maintaining safe and responsible worksites, and in reducing emissions in line with the global push for net-zero.
Social and environmental practices are becoming essential for mining companies to secure a social license to operate. Demonstrating such responsibility helps project approvals go smoother, which directly translates to a faster timeline and profitability.
In this way, intelligent solutions like AspenTech APM and APC not only help keep expenses under control, but add real value for AspenTech’s mining industry clients.
“AspenTech is committed to helping its clients in the mining industry achieve sustainable, cost effective, and optimised operations,” Richardson said.
“The company has a network of experts of who can provide support and guidance throughout the implementation process, ensuring clients get the most out of their investment.”
This feature appeared in the June 2023 issue of Australian Mining.