Overcoming Integration Challenges - PIcontent.pi.tv/events/PI Berlin 2017/presentations/1174_1225 Helena... · Overcoming Integration Challenges Digital Journey ... © Outotec –All

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Helena Gutiérrez & Sami Grönstrand2017 FEB 28PI Berlin

Overcoming Integration Challenges Digital Journey

@PITVtweets #PIBerlin @Outotec


How it all started …


• 1881:

Metallgesellschaft

established

• Metals trading

• Activities expanded to

mining and metallurgical

plants

LURGI METALLURGIE

(Germany)

OUTOKUMPU

(Finland)

• 1910: Orebody found

company established

• 1940’s: Flash Smelting

invented

• 1949 own research

center in Pori, Finland

• Development of

proprietary

technologies

• Internationalization

• Technology sales

starting

• Some spin-offs

• Aqcuisitions starting

• Rammer (Finland)

• Roxon (Finland)

• Wennberg (Sweden)

• Lurgi Metallurgie

focusing on metallurgy

and sulfuric acid plants

• Aisco Systems

(Canada)

• Indepro (Chile)

• Supaflo (Australia)

• Carpco/Inprosys (USA)

1950 - 70’s

1980’s

1990’s

The first 100 years


• KHD Aluminium (Germany)

• Royal Pannevis (Netherlands)

• Nordberg’s Grinding Mills

(USA & Norway)

• Outokumpu Technology

acquires Lurgi Metallurgie

2001 Merger:

Outokumpu

Technology &

LURGI

Metallurgie

2001- 2005

• Boliden Contech (Sweden)

• Millteam (Sweden)

• Ausmelt (Australia)

• Edmeston (Sweden)

• Larox Filters (Finland)

2010-2011

• Kiln Services (Australia)

• Energy Products of Idaho (USA)

• Ash Dec (Germany)

• TME Group (Australia)

• Demil Manutencão (Brazil)

• Numcore (Finland)

• Backfill Specialists (Australia)

2012- 2013

• Scanalyse (Australia)

• Kalogeo (Austria)

• Kempe Engineering (Australia)

• Kovit Engineering (Canada)

• Republic Alternative

Technologies (USA)

2014-2015

• Biomin (South Africa)

• Sinter Plant Services (South

Africa)

• Auburn Group (Canada)

• Outokumpu Technology Oyj listed

on the Helsinki Stock Exchange

2006- 2009

2011:

OPAL

Program

kicked off

2006:

Outokumpu

Technology

IPO

The last 15 years


Outotec Chile Ltda.

Santiago,

Antofagasta, Calama

Outotec Pty. Ltd.

Sydney, Perth, Melbourne

Outotec (RSA) (Pty) Ltd.

Centurion

Outotec GmbH

Oberursel,

Cologne,

Frankfurt

Outotec Tecnologia Brasil Ltda

Belo Horizonte, Vitória

Outotec (Mexico) S.A. de C.V.

San Luis Potosi

ADM

Outotec (Peru) S.A.C.

Lima

Outotec (Shanghai) Co. Ltd

Shanghai, Beijing

Outotec (Canada) Ltd.

Burlington

Outotec Turula Oy

Outokumpu

Outotec Engineering

Services India PVT Ltd

Kolkata

Outotec Oyj

Outotec Minerals Oy

Espoo, Pori

Wintime

Outotec (Kil) AB

Kil, Smedjebacken

Timberline

Outotec Auburn, Inc.

Sudbury

Outotec Filters, Inc.

Jessup, MD

Outotec Filters Oy

Lappeenranta

Outotec

Netherlands B.V.

Utrecht

Outotec (Sweden)

Skellefteå

Outotec (USA)

Denver

Our system landscape in 2011


Global

functions

OPAL - Consolidating our core applications

PDM3D Experience (Enovia)

Plant DMSBlueCielo Meridian

EDMAutodesk Vault

CAD/ CAEInventor/ AutoCAD

EDMSolidWorks Enterprise

CAD/ CAESolidWorks/ AutoCAD

Non-CAD authoring toolsMS Office, etc.

CAD/ CAEOthers

EDMAton*

CAD/ CAESolidWorks/ AutoCAD

EDMAveva

CAD/ CAEAveva

ERPSAP

E - Catalogue

CRMMicrosoft Dynamics

MROMaximo

OSCWedge

RegionsSuppliers Markets

&

customers

Business

areas

Manage and Develop Products

Market

Sell

Deliver Solutions

Deliver Services

Support (F&C, HR, …)

Manage

Supply

Base

Manage

Customer

Relationship

& processes


R&D, sales and service centers in

34countries

Deliveries to more than

80 countries

Sales

1.1 bnEUR in 2016

4,200employees

Listed on Nasdaq Helsinki since 2006

824Patent families

7400 Patents

21 Product Lines

90Products

730Product Models

Outotec today


From Ore to Commodity


The Block Diagram captures the theoretical process steps that are needed to

convert a feed stream into products. The first level of the Plant Structure

represents the Block Diagram.

PRIMARY

CRUSHING

SECONDARY

CRUSHING

CONDITIONING

Cu

REGRINDING

Cu CLEANING

Cu ROUGHING

Mo ROUGHING

Mo

REGRINDING

Mo CLEANING

Feed

ZC02

ZF10

ZF20

ZG20

ZF21

ZF30

ZG30

ZF31

ZC01

Cu concentrate Mo concentrate

Tailings

GRINDING

ZG10

Decoding the process riddle

CADPDM

CRM

Process

calculation


Next, we go into each of the “blocks” represented in the Block Diagram, and find the suitable

combination of equipment to meet each block’s goal. The structure under each of the process

blocks is represented in the Process Flow Diagram (PFD), showing the major type of equipment

that are needed to meet the goal of each block.

GM101 HC101

PS101

GM201

GM202

GM203PS201

HC201

PS001

RC001

FT101

FT102

FT101 FT102 FT103 FT104 FT105

GM101

PS101

HC101

PS001

FT101 FT102 FT103

FT201 FT202 FT203 FT204 FT205

FT301 FT302 FT303 FT304 FT305

FT401 FT402 FT403 FT404

PS101

PS202

PS301

PS401FT501

FT101 FT102 FT103 FT104 FT105FT106 FT107 FT108

FT201 FT202 FT203 FT204 FT205FT206 FT207 FT208

FT301 FT302 FT303

PS102

PS302

PS

001

PS102 PS202 PS302

PS101

GM101

HC101

FT101 FT102 FT103 FT104 FT201 FT202 FT203 FT204 FT205 FT301 FT302 FT303 FT304

PS101

PS402

PS401

PS601

PS701

FT404 FT403 FT402 FT401FT503 FT502 FT501

FT601 FT602 FT603 FT604 FT605

FT701 FT702 FT703 FT704FT705 FT706 FT707

PS201

PS202

Mil

ld

Pb flotation

Cu concentrate

Tailings

ZF21

Solving the jigsaw puzzle

CADPDM

CRM

Process

calculation SAP


Plant

Module

Equipment

Plant unit

Plant Structure

PRIMARY

CRUSHING

SECONDARY

CRUSHING

CONDITIONING

Cu

REGRINDING

Cu CLEANING

Cu ROUGHING

Mo ROUGHING

Mo

REGRINDING

Mo CLEANING

Feed

ZC02

ZF10

ZF20

ZG20

ZF21

ZF30

ZG30

ZF31

ZC01

Cu concentrate Mo concentrate

Tailings

GRINDING

ZG10


How do Ants and Elephants tango?


How do Ants and Elephants tango?


Volume, effective 160 m3Installed power, min 120 kWDiameter, external 5000 mmHeight, Machine Total 8000 mmMaintenance headroom, max 3000 mm Capacity, overhead crane 15 000 kg

Seismic zone UBC 4ATEX area NOSplit for Container Yes

Plant

Module

Equipment

Plant unit

Build

Plant Structure

Equipment BOM

Specifying our equipment in the plant1

2 Selecting our product to meet plant specification

Duty Specification

1st Cleaner Flotation Cells

Pulp flow rate, max 8000 m³/hPulp flow rate, min 4500 m³/hSolid content w/w, max 30%Feed Grade 6,0 % CuConcentrate Grade 10,0 % CuAir Feed rate, Max 12 m3/minMass pull per cell (max) 5 %Mohs hardness 4,5Bond abrasion index 0,37Anticipated Mine Life 25 years

Plant meets product

Product instance

CADPDM

CRM

SAP


Why do we need libraries?

Source: An introduction to iso 15926


Why do we need libraries?

PLMProcess

Datasheet

SupplierDatasheet

ISOStandard

PlantPLM

• The plant library serves as a dictionary for

integration between processes and systems.

• Thereby streamlining interoperability within

the organization.

PLM


Specify-to-OrderEngineer-to-OrderConfigure-to-Order

Drive Assembly

Tank

Walkways and stairs

FloatForce®

Customer specific Piping

Froth handling

FrothSense™

LevelSense™

CellStation™

Process Instruments

Thinking “inside of the box”

Equipment BOM

CADPDM

eCatalogue

SAPCPQ


Product meets lifecycle

Product Project Site

As-Sold As- Engineered As-Manufactured As-MaintainedAs-defined

Product

Portfolio

Project

Portfolio

Installed base

Portfolio

Product Management

Product delivery Installed BaseProduct

Project Services

As-Built As-Modernized De-commissioned

Product meets lifecycle


Connecting the dots

Build a digital online plant representationDefine our products with data

Finetune our simulation modelsComparing theory with reality

Define KPIs to monitor product health

Provide spareparts& services based on

predictive models


Helena Gutiérrez & Sami Grönstrand2017 FEB 28PI Berlin

Overcoming Integration Challenges Digital Journey

@PITVtweets #PIOC @Outotec

Documents

Overcoming Integration Challenges - PIcontent.pi.tv/events/PI Berlin 2017/presentations/1174_1225 Helena... · Overcoming Integration Challenges Digital Journey ... © Outotec –All