ABB inverter and the application of the control system in open-pit mine system upgrade

ABB inverter and control system inverter open-pit mine application ABB applied inverter open-pit mine application ABB in open pit mining and materials transportation system has been widely used. Is put into use for the new equipment, not only for some with decades of old system, through the use of the latest ABB inverter and control technology, can make its regain youth, continue to service for the owners. In this paper, two practical project cases on ABB inverter and the application of control system in open-pit mine system upgrade.

35 years old of skip "second life"

"The restoration results fully shows how to make old lifting bucket shovel continue to restore youth. At present, there are still 17 sets of lifting bucket shovel in the operation and use. To buy a new one similar to skip shovel requires about 30 million euros, and renovation costs just 4 million euros. Transform the 17 units lifting bucket shovel could save 400 million euros, this does not include energy saving, maintenance and recovery time."

Estonia Shale Company (Estonian Oil Shale Company) has four quarry, annual production of about 15 million tons of Oil Shale, is the largest in the Nordic countries, is also one of the most important Oil Shale mine.

Skip shovel used by the user of a complete set of electric system put into use in 1972, has been run before modification for 35 years. - old drive system is still based on motor generator principle of dc drive system, connected by a 2 mva 6 kv synchronous motor three dc generators, dc power supply for all drives. Due to the ac squirrel cage motor has proven to be very reliable, so the owner decided to use ac frequency converter retrofit existing dc system, and replaced the dc motor of ac asynchronous motor. Distribution of all drivers installed on the two adjust the temperature control in the electric cabin, including two sets of the same power supply device and some of the inverter unit, 8 motor drive

Direct torque control (DTC) significantly increased the pull and drag force, provides better performance and constant power characteristics. Due to open pit mine grid, poor quality, so the low harmonic voltage THD (< 5%) and the requirements of voltage fluctuation is very high, in this case, the ABB used active front-end rectifier technology, at the same time, the four quadrant feedback technology, will be generated when the lower the skip and brake energy and give something back to the grid. All frequency converter and other devices are controlled by PLC system, and integrate the ABB advanced diagnostic kits, touch screen control system, thus reducing maintenance workload, improve operational efficiency, reducing the downtime.

The scope

Old dc boost, drag and swing drive device, control system and all cables are removed, replaced with squirrel cage motor, DTC inverter, and PLC control system. According to the size and weight of the new equipment and mechanical basis for the appropriate modification, installed the use of temperature control and purification equipment high-tech electric cabin.

Scope of supply includes dry type transformer, frequency converter, motor, low voltage and medium voltage switchgear, control system, lifting bucket shovel remote monitoring system, cable and engineering design and debugging.

Features of the new system

Old dc system is one of the main problems of the machine running process will produce a lot of electrical spikes, and adopted a reliable feedback loop drive control system, the new system can provide a very smooth operation

New system USES independent digital control system and display system, used to monitor all of the different operating cycle, including running time walk, cycle and bucket number, time and number, etc., as well as the motor temperature monitoring and monitoring of the cooling air flow. The new system will also be able to record and display the consumed and the active power and reactive power, and according to the time the production report accordingly. All information through wireless transmission system to the SCADA system, used to perform productivity analysis, maintenance or repair plan, as well as data archiving, etc.

After modification, significantly increased the reliability of equipment, reduce the maintenance cost, and drive system loss is reduced, can save a year 1 ~ 2 MWh; At the same time, reduce the dynamic load, prolonging the life of the gear box and wire rope cycle; Each operating cycle can be shorten 1 ~ 3 s, thus providing 2 ~ 4% of the productivity; Life cycle of the lifting bucket shovel can be extended for 15 years.

After modification, the lifting bucket shovel has excellent dynamic characteristics and overload characteristics, accurate speed and torque control, can reduce the gearbox by mechanical stress, prolong service life. Its average productivity can be increased 10-40%. The most important thing is that, after the transformation of the energy consumption is 40% less than before.

High efficiency and energy saving "pronouns"

ABB for the Middle East's largest Potash producer (Arab Potash Co., LTD., Arab Potash Co., APC) provides the advanced control system 800 xa and rich experience in mineral processing industry, will help the plant electrical system and the traditional control system upgrade to the most advanced modern technology.

Arab Potash Co., LTD. (Arab Potash Co., APC) is a world leader in mineral processing industry. APC focus on agricultural production in potash, and chemical industry with industrial potash, industrial salt, bromine and mineral fertilizer

APC choose ABB automation system 800 xa extended to the El in the Dead Sea region - Safi systems and solar evaporation pool is located in Aqaba warehouse library of renovation and extension of the control system.

Help the APC company ABB control, drive and instrument system upgrade, make it greatly reduced the factory downtime, lower power consumption, reduce maintenance costs. At the same time, make its factory equipment utilization, material piling and taking speed is greatly increased.

According to the requirements of the contract, ABB provides comprehensive brownfield project factory integrated automation solutions.

ABB offers 800 xa control system, wireless communication network, stacker and reclaimer the dc traction motor drive (figure 5), stacker and reclaimer field sensors, equipment installation and debugging, classroom training and field training facilities and services.

Largest run of the system availability and reliability, prolong the service life of mechanical equipment, comprehensive monitoring and reporting system and significantly reduce energy consumption and operation cost, etc.

Continuous and long-term technical support for customers, have to reduce decision time, smooth transfer process, reduce downtime, according to the production performance appraisal system performance, fast fault diagnosis and troubleshooting and faster pile, such as feeding speed is significant operational efficiencies.