Abstract
The Collahuasi open pit copper mine in Chile has embarked on a groundbreaking journey to enhance its operational efficiency through the implementation of a Digital Twin for its transportation and crushing processes. This presentation will provide a technical overview of the Digital Twin project, focusing on the integration of simulation tools and real-time data to optimize operations, minimize downtime, and reduce the need for physical prototypes.
Process Twin Tool: The Process Twin is a digital simulation tool and a key component of the DigiMine portfolio. By blending the real and digital worlds, it helps plan and optimize operations. The tool simulates the main assets of the mine, allowing for 'what if?' scenarios that can identify and eliminate bottlenecks, leading to optimized asset operation. For instance, work around the crusher at Collahuasi has led to significant production gains of up to 5%.
Key Benefits:
- Operational Optimization: Digital twins are integral to the company's sustainability efforts, optimizing energy consumption, reducing interventions, and enhancing safety. The scenarios visualized through the Digital Twin have provided insights that were previously unattainable and used as soft sensors for the Conveyor. By Simulationg the electrical, mechnaical, and material flow of the crushing and transportation porcess with a long overland conveyor it was possivle to increase the designed capacity of the overall transportation system and to gain real time data out of the soft sensors simulated by the digital twin to get more insights about the operation.
- Collaborative Development: Three work groups have been focused on traffic light algorithmization, failure analysis tools, and the involvement of Innomotics Process from Siemens in the Digital Twin development. This collaborative approach ensured comprehensive feedback and deepened the understanding of the Digital Twin concept.
- Enhanced Training and Safety: The dynamic workshop format facilitated active participation and learning, aligning the team with the development goals of the Digital Twin. This solution is designed to make operations safer, more productive, and beneficial for achieving the company's plans.
Conclusion: The Digital Twin project at Collahuasi demonstrates the transformative potential of integrating advanced simulation tools with real-time data to optimize mining operations. By leveraging the Process Twin tool, the mine has achieved significant improvements in production efficiency and operational safety. This presentation will offer a detailed technical description of the project's components, implementation strategies, and key benefits, providing valuable insights for industry professionals and stakeholders.