过程系统和矿物工程领域的未来自动化系统外文文献

IFAC PapersOnLine 52 25 2019 403 408 ScienceDirectScienceDirect Available online at 2405 8963 2019 IFAC International Federation of Automatic Control Hosting by Elsevier Ltd All rights reserved Peer review under responsibility of International Federation of Automatic Control 10 1016 j ifacol 2019 12 570 2019 IFAC International Federation of Automatic Control Hosting by Elsevier Ltd All rights reserved 1 INTRODUCTION In the context of digital transformation the mining industry is facing significant changes The pace of technological advancement is fast in all megatrends of digitalization which does not center however on technology only but rather on capturing value through improved productivity and performance Based on the survey on digital transformation in the industries more than 1100 executives were interviewed on digital operations and industry 4 0 The most advanced companies distinguished themselves through their mastery of four business ecosystem layers Customer solutions operations technology and people PwC 2018 In the white paper by the world economic forum on Digital Transformation Initiative in Mining and Metals Industry in 2017 four themes are expected to be central Automation robotics and operational hardware digitally enabled workforce integrated enterprise platforms and ecosystems and next generation analytics and decision support The review paper reports more than 320 billion of industry value over the next decade with a potential benefit of approximately 190 billion for the mining sector and 130 billion for the metals sector A reduction of 610 million tonnes of CO2 emissions with an estimated value to society and environment of 30 billion An improvement in safety with around 1000 lives saved and 44000 injuries avoided However the potential loss of about 330 000 jobs or nearly 5 of workforce over the next decade as a consequence of digitalization must be also considered The aim of this paper is to address the role of industry 4 0 in the mining industry by investigating the progresses in Industry 4 0 related research in this industrial sector The results not only summarise the current research activities but indicate existing deficiencies and potential research direction 2 SYSTEM ARCHITETURE FOR PROCESS AUTOMATION REVIEW AND TRENDS Future Automation Systems in Context of Process Systems and Minerals Engineering Prof Sirkka Liisa J ms Jounela Department of Chemical and Metallurgical Engineering School of Chemical Engineering Aalto University Kemistintie 1 02150 Espoo FINLAND e mail Sirkka Liisa Jamsa Jounela aalto fi Abstract The mining industry is confronted with a number of technological challenges along the entire production value chain There is a need for innovative production solutions to bring the next digital generation to the raw material field Industry 4 0 Industrial Internet of Things IIoT Cloud Computing and Artificial Intelligence AI are today the mega trends in the field of process automation In this paper the architecture of the plant automation is studied emphasizing on the future automation systems in context of minerals engineering The state of the art applications of the new technological tools in mining industry are presented and discussed The paper is concluded with a discussion on new research directions in process system engineering motivated by system architectural innovations and Industry 4 0 Keywords Industry 4 0 process automation mining data analytics machine learning future trends 1 INTRODUCTION In the context of digital transformation the mining industry is facing significant changes The pace of technological advancement is fast in all megatrends of digitalization which does not center however on technology only but rather on capturing value through improved productivity and performance Based on the survey on digital transformation in the industries more than 1100 executives were interviewed on digital operations and industry 4 0 The most advanced companies distinguished themselves through their mastery of four business ecosystem layers Customer solutions operations technology and people PwC 2018 In the white paper by the world economic forum on Digital Transformation Initiative in Mining and Metals Industry in 2017 four themes are expected to be central Automation robotics and operational hardware digitally enabled workforce integrated enterprise platforms and ecosystems and next generation analytics and decision support The review paper reports more than 320 billion of industry value over the next decade with a potential benefit of approximately 190 billion for the mining sector and 130 billion for the metals sector A reduction of 610 million tonnes of CO2 emissions with an estimated value to society and environment of 30 billion An improvement in safety with around 1000 lives saved and 44000 injuries avoided However the potential loss of about 330 000 jobs or nearly 5 of workforce over the next decade as a consequence of digitalization must be also considered The aim of this paper is to address the role of industry 4 0 in the mining industry by investigating the progresses in Industry 4 0 related research in this industrial sector The results not only summarise the current research activities but indicate existing deficiencies and potential research direction 2 SYSTEM ARCHITETURE FOR PROCESS AUTOMATION REVIEW AND TRENDS The automation industry has been centered on a five layer hierarchical architecture for years A commonly used architecture model is the five level Purdue Reference Model which later formed the basis for the ISA 95 standard The model is typically expressed as levels from highest to the lowest one Business Systems Plant ERP MRP MES Operation Unit level Machine Process Automation Controller level and Sensor Actuator Level In many industrial visions the traditional automation pyramid structurally separating hierarchical levels has come to its end IIoT Industry 4 0 in Process Industry environment can be considered to include the following main elements The digital automation systems themselves smart equipment and the Internet based cloud borne technology The platform connects the sensors actuators controllers robots etc to computational capabilities residing in Internet based storage and analytics Lin et al 2017 To enable handling of the dynamic engineering processes it is necessary to connect the existing factory automation systems with enterprise resource planning ERP and manufacturing execution systems MES over the IoT infrastructure The challenge is the variety of proprietary control systems in the industry There are various efforts to standardize the interaction but no tracking of the use of standards Reference Architectural Model for Industrie 4 0 RAMI 4 0 is three dimensional Industrie 4 0 2016 The Hierarchy Levels axis represents the different functionalities within factories and uses hierarchies from IEC 62264 standard The Life Cycle digitally enabled workforce integrated enterprise platforms and ecosystems and next generation analytics and decision support The review paper reports more than 320 billion of industry value over the next decade with a potential benefit of approximately 190 billion for the mining sector and 130 billion for the metals sector A reduction of 610 million tonnes of CO2 emissions with an estimated value to society and environment of 30 billion An improvement in safety with around 1000 lives saved and 44000 injuries avoided However the potential loss of about 330 000 jobs or nearly 5 of workforce over the next decade as a consequence of digitalization must be also considered The aim of this paper is to address the role of industry 4 0 in the mining industry by investigating the progresses in Industry 4 0 related research in this industrial sector The results not only summarise the current research activities but indicate existing deficiencies and potential research direction 2 SYSTEM ARCHITETURE FOR PROCESS AUTOMATION REVIEW AND TRENDS The automation industry has been centered on a five layer hierarchical architecture for years A commonly used architecture model is the five level Purdue Reference Model which later formed the basis for the ISA 95 standard The model is typically expressed as levels from highest to the lowest one Business Systems Plant ERP MRP MES Operation Unit level Machine Process Automation Controller level and Sensor Actuator Level In many industrial visions the traditional automation pyramid structurally separating hierarchical levels has come to its end IIoT Industry 4 0 in Process Industry environment can be considered to include the following main elements The digital automation systems themselves smart equipment and the Internet based cloud borne technology The platform connects the sensors actuators controllers robots etc to computational capabilities residing in Internet based storage and analytics Lin et al 2017 To enable handling of the dynamic engineering processes it is necessary to connect the existing factory automation systems with enterprise resource planning ERP and manufacturing execution systems MES over the IoT infrastructure The challenge is the variety of proprietary control systems in the industry There are various efforts to standardize the interaction but no tracking of the use of standards Reference Architectural Model for Industrie 4 0 RAMI 4 0 is three dimensional Industrie 4 0 2016 The Hierarchy Levels axis represents the different functionalities within factories and uses hierarchies from IEC 62264 standard The Life Cycle digitally enabled workforce integrated enterprise platforms and ecosystems and next generation analytics and decision support The review paper reports more than 320 billion of industry value over the next decade with a potential benefit of approximately 190 billion for the mining sector and 130 billion for the metals sector A reduction of 610 million tonnes of CO2 emissions with an estimated value to society and environment of 30 billion An improvement in safety with around 1000 lives saved and 44000 injuries avoided However the potential loss of about 330 000 jobs or nearly 5 of workforce over the next decade as a consequence of digitalization must be also considered The aim of this paper is to address the role of industry 4 0 in the mining industry by investigating the progresses in Industry 4 0 related research in this industrial sector The results not only summarise the current research activities but indicate existing deficiencies and potential research direction 2 SYSTEM ARCHITETURE FOR PROCESS AUTOMATION REVIEW AND TRENDS The automation industry has been centered on a five layer hierarchical architecture for years A commonly used architecture model is the five level Purdue Reference Model which later formed the basis for the ISA 95 standard The model is typically expressed as levels from highest to the lowest one Business Systems Plant ERP MRP MES Operation Unit level Machine Process Automation Controller level and Sensor Actuator Level In many industrial visions the traditional automation pyramid structurally separating hierarchical levels has come to its end IIoT Industry 4 0 in Process Industry environment can be considered to include the following main elements The digital automation systems themselves smart equipment and the Internet based cloud borne technology The platform connects the sensors actuators controllers robots etc to computational capabilities residing in Internet based storage and analytics Lin et al 2017 To enable handling of the dynamic engineering processes it is necessary to connect the existing factory automation systems with enterprise resource planning ERP and manufacturing execution systems MES over the IoT infrastructure The challenge is the variety of proprietary control systems in the industry There are various efforts to standardize the interaction but no tracking of the use of standards Reference Architectural Model for Industrie 4 0 RAMI 4 0 is three dimensional Industrie 4 0 2016 The Hierarchy Levels axis represents the different functionalities within factories and uses hierarchies from IEC 62264 standard The Life Cycle the Industrial Internet Consortium IIC has reported a reference architecture called the Industrial Internet reference Architecture IIRA IIRA is a standard based open architecture for IIOT systems It provides an architecture framework to design industrial internet systems without making specific recommendations for standards or technologies that comprise these systems Core to IIRA is the different business and technical perspectives described as viewpoints for identifying and addressing architectural concerns The Industrial Internet Connectivity Framework IICF published by IIC extends the IIRA to map the IIOT connectivity It clarifies IIOT connectivity with a new IIOT stack model defines an open connectivity reference architecture and helps practitioners to categorize evaluate and determine the suitability of a connectivity technology for the IIOT system at hand Both IIRA and RAMI4 0 have been created with the same goal towards the convergence of Information Technology IT and Operational Technology OT 3 INDUSTRY 4 0 IN MINING CHALLENGES AND OPPORTUNITIES Digital transformation Industry 4 0 and emerging networking technologies provide mining industries many benefits such as productivity sustainability and safety The mining companies are investing digital technologies in their operation most in automation and robotics control remote operating centers and wearables From robotic drills to self driving ore trucks automation is bringing a new measure of safety to mines and boosting the efficiency Mining automation appearing in the form of self driving ore carrying vehicles use the same technologies seen in other autonomous vehicles Rio Tinto uses more than 80 of these three story high trucks at its iron ore mines in western Australia Autonomous vehicles are also venturing underground With their laser scanners and radar they can move around safely and quickly in narrow dusty tunnels where humans have trouble navigating In the comfort and safety remote control room operators can simultaneously control and monitor the movements of a fleet of driverless loaders or trucks deep below the surface or drill rigs on the surface For data analytics and optimization of mine operations there are many commercial tools in the market by which data analytics can be made 3D Mine Visualizer Drill Plan Visualizer Sceduling task management real time location tracking and monitoring for all mobile fleet on 2D 3D models of the mine The solutions provide the transparency of underground operations and enable joint development of mining process efficiency supported by remote service centers Robots are used to monitor mining operations some move through underground mines collecting data on the temperature rock stability and other conditions that might affect worker safety There are also research programs testing robots that can extract ore underwater The robots resemble the road header machines used to cut rock in today s mines They use their spiked heads to pulverize the ore with the resulting slurry pumped to the surface Automation means the mines of the future could exist on the ocean floor and even in space You can operate these robots remotely from halfway across the world Freeport McMoRan uses drones to more closely monitor and evaluate the rock face at its mines in real time as it blasts away rock to build mine slopes The data driven approach enables more precise reading to companies to build deeper slopes ultimately displacing less rock and expending fewer resources to access the ore body Drones can take pictures and real time videos for monitoring blasting operations environmental conditions and mine security Improvement in connectivity and breakthroughs in other technologies such as wearable technologies the Internet of Things virtual reality and augmented reality open up further opportunities for innovations in the mining industry Connected mobility and connected worker technologies have numerous applications Equipping workers with connected intelligent wearables and mobile devices allows mine management to capture information in real time It also enables seamless communication immediate remote expert assistance diagnosis and real time guidance or access to instructions to repair fault equipment Cloud based IIoT platforms collect and share data of themselves and their surroundings in the mines to allow widespread monitoring analyzation optimization and control Industrial platforms used in the mining industry applications are for examples Connected Mine Hitachi Lumada IoT Schneider Electric IoT GE Digital Predix open Siemens MindSphere C3 IoT SAP Leonardo IoT Metso Metrics FactoryTalk ABB Ability Intelligent Mining Solution Hexagon Mining Logimine Horozon Modular Mining Sandvik s AutoMine Dispatch and Kaa IoT open 4 STATE OF THE ART IN MONITORING AND CONTROL OF MINERAL PROCESSING 4 1 Benefits of advanced control strategies IFAC MMM TC conducted comprehensive surveys on process control and automation in mineral and metal processing reporting the great economic benefits of the applications Hodouin et al 2001 Bergh et al 2001 Bouffard presented his review on the benefits of control strategies of about twenty milling operations in 2015 describing some very superior operational performance 1 16 gain in ore throughput at least 40 reduction in mill load variability up to 1 in metal recovery in flotation and reduced operating costs 15 reduction in grinding media consumption 52 reduction of the cyclone pressure vari ability A comprehensive list of the plant implementations type of the control strategies and methods with their economic records are given in his review article in detailed 4 2 Modelling and simulation Sirkka Liisa J ms Jounela IFAC PapersOnLine 52 25 2019 403 408 405 Simulation for process design and optimisation is today an established technique as evidenced by it