|dc.description.abstract||A management system following ISO 50.001 is proposed for improving the performance and energy efficiency in mineral processing applications. The proposed scheme includes a total productive maintenance (TPM) approach, employing the current organizational levels of working teams. Project management can be enhanced, from diagnostics and scoping to implementation stage, fostering the innovation road based on operational knowledge with process modeling, analysis, measurement and verification of KPI’s.
The presented scheme follows continuous improvement methodology, taking into account the goal of sustainability with issues of energy efficiency and emissions abatement as new requirement and opportunities. It states the working hypothesis concerning the close relation between productivity and energy efficiency in industrial facilities with energy intensive process. In other words, a working strategy for improving energy efficiency will enable very likely an improvement in productivity, and conversely.
The general problem of energy efficiency may be formulated as an optimization problem. In the mining industry it is stated as part of mine-to-mill integration, with mine planning, fragmentation, loading, transportation, crushing and further processing to the concentrator in the case of copper sulfides. Therefore, first activity is to actualize a survey and diagnostic with the central question about how far is an existing plant operation from the best possible “ideal” one. Currently, mineral processing facilities may not be operating at optimal conditions, for different reasons. Among others, because of complexity, distributed systems and harsh environment, push priorities for rugged and simple equipment, but with lack of devices, sensors, instrumentation and control system for integration at the plant level.
Following the strategy of 80-20 rule, a ranking of productive issues may be identified and their related projects. Therefore, a strategy with gradual applications will starting with focus on critical paths and bottle-necks of process, conducting to the search of reliability and plant stability, with downtimes reduction, losses mitigation and local optimization as a first steps towards a global optimal strategy. Two industrial application cases for initial and local optimization issues are presented, showing the use of the proposed scheme. Incorporation of abilities from suppliers and consultors for providing dynamics in innovation and current efforts for further developments and contributions are also discussed.
Keywords: Energy efficiency, process optimization, modeling and simulation, smart systems||es_CL