IRON ORE PROCESSING

STAGE 1B
AT
AFRICAN MINERALS LTD.,
TONKOLILI
Overview of Presentation
Industry Overview
Process Overview
Iron ore Process
Project Overview
System Architecture
Softwares used
PLC Code Programming Structure
SCADA

Industry Overview
African Minerals has been active in Sierra
Leone since 1996.
Phase I production capacity increased from
15Mtpa to 20Mtpa and low cash costs expected
at under $30/t..



Industry Overview

Established in 1991 .
Mining industry experts - for the delivery of turnkey
Mining process projects.
AML Plant total designed by Ausenco.


Industry Overview
LV Systems
Instrumentation
Control Systems
Plant Management Systems
Support & Maintenance
Plant Installations
What is Iron Ore??
Iron ore is any rock or mineral from which
iron can economically be extracted form
of iron oxides such as magnetite.
Ore contain between 25% to 60% iron.







Iron Ore Process
overview
Iron Ore Process
ROM bin continuous level transmitter Lo Level to
activate Green light for front end loaders to fill the
ROM bin.
Hi Level to activate Red light for front end loaders to stop
filling the ROM bin
Apron Feeder
Speed Controlled by WIC in Automatic mode, or Operator set
point in Manual
Roller Screen
Roller Screen Contain 8 motors. If any motor stopped due to
Motor jam. Then all 8 motors stop and wait 5 sec Restart the
Roller in Reverse. Run the Roller in Reverse for 10 seconds
Stop the Roller for 5 seconds. Start the Roller Forward. All the
operation in Auto mode
Iron Ore Process
Over Land Conveyer after primary crushed iron
ore Transfer to Scrubber by using over land
conveyer.
(2.5 Km Power Regeneration Drive)

The Over Land Conveyer generated
1 Mw Power.
DOUBLE ROLLS CRUSHER
The drive cannot be started/stopped individually from the
PCS. The Crusher Drives Will Start and Stop as One Drive
Iron Ore Process
Scrubber Feed Diverter Chute
Move to Dump position when either Scrubber, CV003,
Screen1 or Process water pumps any one stop Diverter Chute
move to Dump position
Iron Ore Process
Crushed ore delivered from the
overland conveyor discharges into
the scrubber where process water is
added. The ore is scrubbed and clay
minerals are washed from the ore
surface before discharging from the
scrubber via the discharge trammel,
which has a screen aperture size of
32mm. The trammel oversize
material discharges to the cone
crushing circuit while the undersize
material gravitates to the coarse
screen.
Scrubber
Iron Ore Process
Tailing Thickener
The coarse screen (8mm aperture) oversize discharges onto the
lump product conveyor, and undersize slurry gravitates to the
fines dewatering cyclones feed hopper. Slurry from the fines
dewatering cyclones hopper is pumped in two parallel closed
circuits of feed pumps, dewatering cyclones and dewatering
screens. Overflow from the cyclones discharges to the tailings
thickener.
Thickener under flow
There are three thickener underflow pumps, each with
dedicated discharge lines to the tailings hopper. To enable
recycling of slurry back to the thickener, when required, two
of the pumps are provided with recycle lines to the thickener
feed tank.
All three of the pumps can be variable speed controlled and
have dedicated Flow & Pressure Cascade control loops. The
number of pumps required to run at any one time will depend
upon the ore type being fed into the process. More pumps will
be required to run if the ore contains a large amount of fine
material.
Iron Ore Process
From Scrubber over Size ore going to
Cone Crusher and Normal Size go to
Dry Screen. Cone Crusher Crushed the
ore and send to Dry Screen. After
Screen Lump Ore transfer to Lump
Product House.
Cone Crusher
Controlled by vendor supplied LCP but remotely started and
stopped from the PCS. The amount of cone crushers to run
will be determined and selected by the operator based on the
type and amount of ore being fed to the process. The cone
crusher is selected to Auto on the LCP if it is required to start
and stop remotely.
Iron Ore Process
From Product House to Stock Dump
yard going through Stackers
(Lumps & Fines).
Stackers
The finished Iron Ore transferred
to Port by Train.
And Fine direct Separated from
Scrubber Outlet its transfer to fine
Product house.
IRON ORE PROCESSING
STAGE 1B
AT
AFRICAN MINERALS LTD.,
TONKOLILI
The Aim of This Project was :-
1. To reduce the Time and Logistic
This Process plant to increase in production
1800Tph.
Overall increase in capacity 15Mtpa to
20Mtpa .
System Architecture
This project utilizes Schneider-Quantum-140 CPU
652 60 02.40, No- 4 PLCS
ModiconM340-BMX P34 2020 02.10, No-4 PLCs
Software-Unity Pro XL V 6.0,Vijeo Citect 7.2,
Pro Soft V 2.3.2.2, Power Suite v 2.6.1.
System Architecture
FO
Primary Crusher
Area
Dry Screen Area
Raw Water Area
Jozi Power Area
Server Room
EH
Op station 2 Op station 1 Engg station
Scrubber Area
Scrubber Area PLC Configuration
Schneider-Quantum-140 CPU 652 60 02.40, No- 2 PLCS
PLC-1
Digital IP-2M-64 I/O
Analog IP-2M-32 I/O
Digital OP-1M-32 I/O
Analog OP-2M-8 I/O
PLC-11
Digital IP-2M-64 I/O
Analog IP-2M-32 I/O
Digital OP-1M-32 I/O
Analog OP-3M-12 I/O
Dry screen & Primary Area PLC Configuration
Schneider-Quantum-140 CPU 652 60 02.40, No- 1 PLC
PLC-2
Digital IP-4M-128 I/O
Analog IP-1M-16 I/O
Digital OP-1M-32 I/O
Analog OP-1M-4 I/O
Schneider-Quantum-140 CPU 652 60 02.40, No- 1 PLC
PLC-4
Digital IP-4M-128 I/O
Analog IP-1M-16 I/O
Digital OP-1M-32 I/O
Analog OP-1M-4 I/O
Jozi power & Raw water Area PLC Configuration
ModiconM340-BMX P34 2020 02.10, No- 1PLC
PLC-96
Digital IP-2M-32 I/O
Analog IP-3M-12 I/O
Digital OP-1M-16 I/O
Analog OP-1M-4 I/O
ModiconM340-BMX P34 2020 02.10, No- 1PLC
PLC-91
Digital IP-1M-16 I/O
Analog IP-2M-8 I/O
Digital OP-1M-16 I/O
Analog OP-1M-4 I/O
ProfiBus Communication module
ProfiBus Communication module
Supporting for Schneider PLCs
Baud Rate Support Up to 12,000 K Bit/Sec
ProSoft Configuration
ProfiBus Communication
ProSoft Description
TeSys T Protection Relay
Spider controller for Scrubber
Siemens CP 342-5 for Cone Crusher
Control Techniques Unidrive SP for VSDs
This all GS* files
All the above GS* files Communicated with Schneider PLCs
PLC Programming Structure
Sequence logic was distributed in different Section
known as the.
Analogs:A1061LIT6102.
PID Loops:A1051FIC5126.
Drives:A1051PU15.
Valves:A1051XV5145.
E.g. Analogs:A1061LIT6102
A1061- Area, LIT- Instrument, 6102- Number
PLC Programming Structure
Sequences are known as the -
Sequence:SQPU038_STT.
Sequence:SQPU038_STP.
E.g. Sequence:SQPU038_STT
SQ-Sequence, PU038-Pump Number, STT-Start
PLC Code Structure
PLC Code for Analogs
PLC Code for PID Loops
PLC Code for Drives
PLC Code for Valves & Sequences
PLC Code for inter PLC communication
BIT9 A1012CV002BRS2FLT
BIT11 A1012CV002BRS6A
BIT4 A1012CV002BDS8A
BIT7 A1021SB001_RUNUP
BIT12 A1012ZSH1282
BIT14 A1012ZSH1284A
BIT6 A1012CV002BDS10A
BIT1 A1012CV002BDS5A
BIT10 A1012CV002BRS5A
BIT3 A1012CV002BDS7A
BIT15 A1012ZSH1284B
BIT13 A1012ZSH1283
BIT5 A1012CV002BDS9A
BIT2 A1012CV002BDS6A
BIT8 A1012CV002BRS2RLS
BIT0 %S6 OUT
.31
BIT_TO_WORD
16
BIT9 A1021PU088_RUNUP
BIT11 A1021PU089_RUNUP
BIT4 A1022CR003_RUN
BIT7 A1022CR004_RUNUP
BIT12 A1021PU090_RUN
BIT14 A1012ZSO1293A
BIT6 A1022CR004_RUN
BIT1 A1012ZSO1285
BIT10 A1021PU089_RUN
BIT3 A1012ZSO1292A
BIT15 A1012ZSO1294A
BIT13 A1021PU090_RUNUP
BIT5 A1022CR003_RUNUP
BIT2 A1012ZSO1291A
BIT8 A1021PU088_RUN
BIT0 A1012ZSH1284C OUT
.32
BIT_TO_WORD
20
REAL_IN
BOOL3_IN
BOOL4_IN
BOOL1_IN
BOOL2_IN
INT_IN
PUB_OUT PLC1_EGD
FBI_230
COMMS_PUB
22
BIT9 A1022CV003_RUNDN
BIT11 A1072CV010_SEQSTP_TPLC2
BIT4 A1072ST002_AUTOSTT_HMI_TPLC2
BIT7 A1022CV003_SEQRDY
BIT12
BIT14 A1072ST002_AUTOSTP_TPLC2
BIT6 A1072CV010_AUTO_TPLC2
BIT1 A1072ST002_BELT_STT_TPLC2
BIT10 A1072CV012_SEQSTP_TPLC2
BIT3 A1072CV010_SEQSTT_TPLC2
BIT15 A1023CV006_RUNUP
BIT13 A1072ST002_BELT_STP_TPLC2
BIT5 A1072CV012_AUTO_TPLC2
BIT2 A1072CV012_SEQSTT_TPLC2
BIT8 A1022CV003_RUNUP
BIT0 A1072ST002_AUTOSTT_TPLC2 OUT
.1
BIT_TO_WORD
17
BIT9 A1021FIC2102_LLA
BIT11 A1061PU056_RUNUP
BIT4 A1021SC001_RUNDN
BIT7 A1022CV003_RUN
BIT12
BIT14
BIT6 A1061PU045_SEQSTP_TPLC11
BIT1 A1023CV006_SEQRDY
BIT10 A1061PU001_RUNUP
BIT3 A1021SC001_RUNUP
BIT15
BIT13
BIT5 A1061PU020_SEQSTP_TPLC11
BIT2 A1021SC001_SEQRDY
BIT8 A1021SC001_RUN
BIT0 A1023CV006_RUNDN OUT
.2
BIT_TO_WORD
21
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH17
CH18
CH19
CH20
CH21
CH22
CH23
CH24
CH25
CH26
CH27
CH28
CH29
CH30
CH31
CH32
INT_Array
FBI_231
PUB_INT
18
CH1 TMWG
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH17
CH18
CH19
CH20
CH21
CH22
CH23
CH24
CH25
CH26
CH27
CH28
CH29
CH30
CH31
CH32
REAL_Array
FBI_232
PUB_REAL
19
Publ i sh Data

PLC Code for inter PLC communication
Data_IN
INT_CH_3
INT_CH_31
INT_CH_28
INT_CH_22
INT_CH_25
INT_CH_19
INT_CH_16
INT_CH_13
INT_CH_7
INT_CH_10
INT_CH_4
INT_CH_1 A1022WQIT2229_RAWPV
INT_CH_32
INT_CH_29
INT_CH_26
INT_CH_23
INT_CH_17
INT_CH_20
INT_CH_14
INT_CH_11
INT_CH_8
INT_CH_2
INT_CH_5
INT_CH_27
INT_CH_30
INT_CH_24
INT_CH_21
INT_CH_18
INT_CH_12
INT_CH_15
INT_CH_9
INT_CH_6
FBI_1953
COMMS_INT
4
RSTI
IP3 2
IP4 22
IP1 10
Chn1Data PLC2_EGD
StartAddress 1200
IP2 0
Data PLC2_Data
Comms_Dest PLC2_COMMS
Al armChn1 PLC1R2_CommsChn1A
Al armChn2 PLC1R2_CommsChn2A
Al arm PLC2_CommsA
FBI_1927
COMMS_SELECT
1
PUB_OUT
REAL_CH_3
REAL_CH_31
REAL_CH_28
REAL_CH_22
REAL_CH_25
REAL_CH_19
REAL_CH_16
REAL_CH_13
REAL_CH_7
REAL_CH_10
REAL_CH_4
REAL_CH_1 A1023WIT2329_PV_FPLC2
REAL_CH_32
REAL_CH_29
REAL_CH_26
REAL_CH_23
REAL_CH_17
REAL_CH_20
REAL_CH_14
REAL_CH_11
REAL_CH_8
REAL_CH_2 A1023WIT2339_PV_FPLC2
REAL_CH_5
REAL_CH_27
REAL_CH_30
REAL_CH_24
REAL_CH_21
REAL_CH_18
REAL_CH_12
REAL_CH_15
REAL_CH_9
REAL_CH_6
FBI_1952
COMMS_REAL
3
Data_IN
BOOL_CH_3 A1072CV010_RUN_Comms
BOOL_CH_31
BOOL_CH_28
BOOL_CH_22
BOOL_CH_25 A1022CV004_RUN
BOOL_CH_19 A1021SC001_SEQSTT
BOOL_CH_16 A1022CV003_SEQSTT
BOOL_CH_13 A1072ST002_ILOC_FPLC2
BOOL_CH_7 A1072CV010_RUNDN_FPLC2
BOOL_CH_10 A1072CV012_RUNDN_FPLC2
BOOL_CH_4 A1023CV006_SEQSTT
BOOL_CH_1 PLC2_Watchdog
BOOL_CH_32
BOOL_CH_29
BOOL_CH_26
BOOL_CH_23
BOOL_CH_17 A1022CV003_SEQSTP
BOOL_CH_20 A1021SC001_SEQSTP
BOOL_CH_14 A1072ST002_IRDY_FPLC2
BOOL_CH_11 A1072CV012_RUNUP_FPLC2
BOOL_CH_8 A1072ST002_IRUN_FPLC2
BOOL_CH_2 A1071CV007_RUN_Comms
BOOL_CH_5 A1023CV006_SEQSTP
BOOL_CH_27
BOOL_CH_30
BOOL_CH_24
BOOL_CH_21
BOOL_CH_18 A1021SC001_AUTO_FPLC2
BOOL_CH_12 A1072CV012_SEQRDY_FPLC2
BOOL_CH_15 A1022CV003_AUTO_FPLC2
BOOL_CH_9 A1072CV010_SEQRDY_FPLC2
BOOL_CH_6 A1023CV006_AUTO_FPLC2
FBI_1954
COMMS_BOOL1
5
PLC2 recei ved data

Data_IN BOOL_CH_33
BOOL_CH_34
BOOL_CH_35
BOOL_CH_36
BOOL_CH_37
BOOL_CH_38
BOOL_CH_39
BOOL_CH_40
BOOL_CH_41
BOOL_CH_42
BOOL_CH_43
BOOL_CH_44
BOOL_CH_45
BOOL_CH_46
BOOL_CH_47
BOOL_CH_48
BOOL_CH_49
BOOL_CH_50
BOOL_CH_51
BOOL_CH_52
BOOL_CH_53
BOOL_CH_54
BOOL_CH_55
BOOL_CH_56
BOOL_CH_57
BOOL_CH_58
BOOL_CH_59
BOOL_CH_60
BOOL_CH_61
BOOL_CH_62
BOOL_CH_63
BOOL_CH_64
FBI_1955
COMMS_BOOL2
2
PLC2_Data PLC2_Data PLC2_Data PLC2_Data
Analogs & Drives Popup
Analogs Motors & Pumps Conveyers VSDs
PID Loops
Valves & Sequences
Presentation Prepared By GHT
Thanks for your attendance.