Sudbury Nickel Mine Achieves Optimal Levels of Productivity

with Comprehensive Control and Information Solution

Greenfield Project Serves as Benchmark for Future Mine Development

Challenge
Provide mine-wide control and
information solution for greenfield
nickel ore mine

Solutions
Integrated Architecture System
One integrated system optimizes
discrete and power control through
Intelligent Motor Control as well
as process applications
Modular underground control
substations streamline
implementation and minimize
infrastructure requirements
Supervisory-level visualization
capabilities provide operators
with optimal insight into
process information An integrated, mine-wide Rockwell Automation solution has optimized operations
Thin client single mode EtherNet/IP at this nickel mine in Sudbury, Ontario.
infrastructure meets long distance
communication requirements via
wired and Wi-Fi transmission
Background
Results
The mineral-rich Sudbury basin, located in northern Ontario, Canada,
Optimized overall system visibility
boasts extensive deposits of nickel, copper, platinum, palladium and
and efficiency
gold. Since 1929, this region has boasted an extensive network of mines,
Enabled system flexibility and mills and smelters.
scalability and ability to extend
integrated solution to other parts In 2003, the primary mining company in the region solidified plans to
of the operation quickly expand its operations in the northeast edge of the basin. Development of
the US $840-million greenfield project began in 2004. Built for an annual
capacity of 1.25 million tonne of nickel, copper and platinum-group ores,
the new underground mine was slated to begin production by 2011.
Challenge
Historically, the mining industry is particularly vulnerable
to fluctuations in the global commodities market. In fact,
when prices plummet, mining companies often find that
marginally efficient operations are no longer profitable and
choose to suspend extraction until the market rebounds.
To justify the development of the project, the Sudbury
mines leadership stipulated that the new operation
incorporate advanced technologies to enable efficient
and thereby profitable operation in virtually any
commodities market.
The mines operators chose Hatch, an engineering,
procurement and construction management (EPCM) firm,
to develop the project. Headquartered in Ontario, Hatch
is a global engineering company that has served the
mining and metals industry for more than 50 years.
From the onset, the end user had a vision to develop
an innovative, future-ready mine, said Josh Lilley, lead
engineer, Hatch. To do so, the company knew it had to
exploit the full potential of automation throughout the
mining process both above ground and at depths
1,700 meters below the surface.
In particular, the company hoped to incorporate the latest
automation and communication capabilities to optimize
productivity, improve process variability and capture the
advantages of mobile technology.
From a systems and process control perspective, the
scope of the project was extensive and included: a real-
time data management infrastructure; RFID equipment
and personnel tracking; the ventilation on demand (VOD)
system; automated mine hoisting; and remote static and
mobile equipment controls.
While each specific application presented unique
challenges, energy and resource utilization was a common
concern throughout the mine.
In specifying a control system, Hatch required an
integrated solution that could address a wide range of
control applications.
Keep in mind, a mine is also a continuous construction
site, said Lilley. The selected control solution had to
incorporate flexibility to adjust to these constant changes
cost-effectively.
Solution
After evaluating a number of control systems, the Hatch
team recommended a mine-wide Rockwell Automation
solution based on the Integrated Architecture system.
It was clear that a Rockwell Automation control solution
would match the technology vision for the mine,
said Lilley. Rockwell Automation offers a consistent,
integrated system that would optimize discrete and
power control as well as process applications.
The backbone for the solution is the communication
infrastructure, which consists of a redundant, single
mode EtherNet/IP network. Via both wired and Wi-Fi
transmission, this IT infrastructure handles all surface and
underground communication and enables high-level
process and business data sharing on a common, centrally
managed architecture.
Rockwell Automation could support
all applications throughout the mine
within this cost-effective environment
and allow us to create a real-time
management infrastructure.
Josh Lilley
We designed our solution based on thin client
architecture, Lilley said. Rockwell Automation could
support all applications throughout the mine within
this cost-effective environment and allow us to create a
real-time data management infrastructure.
Rockwell Automation control systems were deployed
throughout all areas of the mine. The integrated
supervisory control and data acquisition (SCADA) solution
includes Allen-Bradley ControlLogix programmable
automation controllers (PACs), low voltage and medium
voltage Allen-Bradley PowerFlex variable frequency
drives, Allen-Bradley E3 Plus solid-state overload
relays, FactoryTalk View Site Edition (SE) supervisory
HMI software and Allen-Bradley PanelView Plus
graphic terminals.
All mining operations require an extensive control
infrastructure. To streamline development, the Hatch-
Rockwell Automation team designed a standard,
DeviceNet configuration for all underground substations
and employed a modular approach.
Actually, we worked with Hatch to design portable
control centers, explained Bob DaPrat, account manager,
Rockwell Automation. By designing control capabilities in
various blocks related to specific functions, we were able
to minimize some of the infrastructure requirements.
Built to withstand underground conditions, the portable
substations were delivered as modular systems. Sling or
fork-lift ready, the skidded systems could be moved to
provide needed power control as construction progressed
throughout the mine while leaving control for essential
functions (e.g. lighting) in place.
To ensure a standard control and visualization
environment throughout the operation, Hatch worked
closely with an embedded Rockwell Automation engineer
to deploy standard function blocks/add-on instructions
(AOIs) and faceplates.
The projects goal was to deliver an HMI system based on
the best practices of the industry, said Lilley. FactoryTalk
software allowed us to achieve that goal and provides the
end user with seamless systems monitoring and control of
mine processes.
In addition, a third-party remote equipment tracking
system was integrated into the SCADA solution.
Results
The project was commissioned on schedule and below
budget in 2011 and has been meeting productivity goals
ever since.
The end user planned to create a technology benchmark
for future mine development, said Lilley. This project
allowed us to achieve their goal.
The Rockwell Automation control solution provides an
integrated view into the entire mining process both
above ground and below. And the state-of-the-art power
control technologies implemented throughout the mine
have been instrumental in helping the mine achieve
energy efficient operation.
In addition, the modular control substations have
continued to prove valuable as mine development
expands at the site.
The modular substation approach is something we plan
to leverage in future mine developments as well, said
Lilley. These flexible, pre-built systems allow us to achieve
underground control quickly and cost-effectively
expand capabilities as needed.
The results mentioned above are specific to the end users use of Rockwell Automation
products and services in conjunction with other products. Specific results may vary for
other customers.

The Rockwell Automation control solution provides an integrated view into the entire
mining process both above ground and below. And the state-of-the-art power control
technologies implemented throughout the mine have been instrumental in helping the
mine achieve energy efficient operation.
Allen-Bradley, ControlLogix, E3 Plus, FactoryTalk, Integrated Architecture, PanelView, PowerFlex and Rockwell Software, are trademarks of Rockwell Automation Inc.
DeviceNet and EtherNet/IP are trademarks of Open DeviceNet Vendor Association.

Publication MFGVP-AP009A-EN-P June 2014 Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.