A digital pioneer – Australian Mining

FLSmidth has become a key partner to the Australian mining industry as the sector embarks on a digital transformation.

FLSMidth (FLS) has been a digital pioneer since the invention of the first computers, its cement origins requiring the adoption of pioneering technologies.

In 1969, the same year Neil Armstrong set foot on the moon, FLS developed a digital solution to automate quality assurance in cement production.

The small computer could store up to 16 kilobytes (kB). As a reminder, the computer that carried astronauts to the Moon in 1969 had a maximum capacity of 72 kB, while a modern smartphone has a memory of at least 64 gigabytes.

More than 50 years later, FLS continues to leverage its digital ingenuity to increase productivity and efficiency in the mining industry.

While digitalisation is not new to the Australian resources sector, it is an ever-changing landscape.

“Digital is not new, but it is new in terms of the relationship between the provider and the user,” said Julio Rodriguez, regional head of FLS’s digital product line Asia Pacific. Australian Mining. “In this case, the mining companies and FLS as a technology provider.

“The way the user and the provider interact is new, and so we often ask ourselves, ‘How can we structure ourselves internally to best interact with and meet customer needs?’”

For digital offerings to achieve maximum adoption, vendors must understand their customers’ digital maturity, while ensuring that their digital products are complementary for a given customer.

As it continues to develop its digital portfolio to adapt to technological advancements in the mining sector, FLS continues to evolve the way it supports its customers.

“We view digital as a service, not a product,” Rodriguez said. “And we strive to partner with our customers to ensure we work with them throughout their digital journey.”

“This is not a transactional relationship, but rather a continuous feedback loop between the original equipment manufacturer (OEM) and the customer, where we continually work together to find improvements to a solution.

“This is part of our MissionZero mine, which focuses on efficiency, water management and license to operate from a customer perspective. We are using digital to achieve this.”

Through the MissionZero mine, FLS has set a goal of achieving zero-emission mining through its solutions by 2030. The OEM aims to help miners produce more with fewer resources to create a smaller footprint and reduce operational expenses.

“One solution that fits into the MissionZero framework is PerformanceIQ, a consulting and service support program for digital technology adoption,” Rodriguez said.

“We analyse customer data and provide insight into how an operation is performing and where there are potential weaknesses that could cause downtime. It’s also about ensuring that a mine site is operating as efficiently and productively as possible.

“We have adopted PerformanceIQ in conjunction with Tier 1 miners in North and South America with great success.”

PerformanceIQ leverages machine learning and artificial intelligence to continuously optimize performance. Its goal is to close the gap between current performance levels and the ambitious operational goals that mining companies are setting to meet increasing boardroom expectations.

The PerformanceIQ solution begins with a bottleneck analysis. FLS examines the various inputs to a mining process, from materials to process control technologies and people, and performs a comprehensive audit and technical analysis of operational and maintenance processes.

The manufacturer then develops solutions with its customers and identifies opportunities for significant improvements. This could mean adopting FLS’s LoadIQ smart sensor solution, which ensures operators are making optimal use of their crusher, or implementing remote health monitoring services.

Alternatively, PerformanceIQ may determine that an equipment upgrade is necessary to avoid failures and downtime in the future.

Opportunities are prioritized based on financial impact and time to delivery, and lessons are implemented with guidance and training from FLS PerformanceIQ experts.

The service doesn’t stop there, as FLS continues to work with its clients to monitor results and make adjustments as needed.

With a strong international PerformanceIQ customer base, FLS is keen to expand the solution’s presence in Australia.

“In Asia Pacific, particularly in Indonesia and Australia, we are starting to see more customers inquiring about PerformanceIQ,” Rodriguez said.

“Tier 1 miners have historically done their technical analysis in-house, but even they are starting to see the benefits of partnering with third parties.

“A unique perspective can help operators avoid sophisticated maintenance issues, especially when the advice comes from their equipment manufacturer.”

The best operational results are achieved when a miner and OEM rely on each other to find the root of a problem and develop the best course of action.

“You need the pure perspective of the original equipment manufacturer, because they know every bolt of the system, but you also need the customer, because they know exactly how and why they use a piece of equipment,” Rodriguez said.

“When you have that alliance between the customer bringing their operational know-how and the OEM bringing their machine know-how, that’s where you see success.”

This article appeared in the July 2024 issue of Australian Mining.