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Next Generation Automation for the Mining Industry enabled by Industry4.0 technologies Sam G. Bose Founder & CEO presented to: presented by: C4IR: Executive Master Class Presented at Consortium for the 4th Revolution | Executive Briefing Day (#C4IR) Cambridge, UK 2-3 February 2017 | www.cir-strategy.com/events

Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

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Page 1: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Next Generation Automation for the Mining Industry enabled by Industry4.0 technologies

Sam G. Bose Founder & CEO

presented to:

presented by:

C4IR: Executive Master Class

Presented at Consortium for the 4th Revolution | Executive Briefing Day (#C4IR) Cambridge, UK 2-3 February 2017 | www.cir-strategy.com/events

Page 2: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Agenda

• About IntelliSense.io

•  Industry 4.0 Technologies and it’s relevance for Mining Industry now?

• Case Study: Copper Mining in Chile

• Questions and Answers

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Page 3: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

IntelliSense.io: Empowering People & Machines to make better decisions

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Academic Alliance:

Expertise: Internet of Things, Sensor Data Analytics & Decision Support Natural Resources Industry (Mining, Oil & Gas)

Founder & CEO: Sam G. Bose

HQ: Cambridge UK

Operations

Dev Center

Operations

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IntelliSense.io: Our Customers

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Key Partners

Chile / Latin America Kazakhstan / Central Asia

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What is Internet of Things? Transformation of any physical object to digital data object by attaching sensors and communications to it.

Computing Era Transformation

2016 +

•  6.4 billion internet connected things in 2016, up 30% from 2015 (Source: Gartner)

•  More Data created in the past 2 years than entire history of human race, but less than 0.5% of all data is ever analysed (Source: Fortune)

•  Industry-wide (Oil & Gas, Mining) adoption of IoT technology could increase global GDP by as much as 1.2 percent, or $930 billion during the next decade (Source: Oxford Economics, McKinsey)

IoT Today

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Page 6: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

What is Industry 4.0?

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Industrial Internet of Things IND

US

TRY

1st REVOLUTION 2nd REVOLUTION 3rd REVOLUTION 4th REVOLUTION

Water/Steam Electricity Automation Intelligence Era

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Applying Internet of Things & Artificial Intelligence technologies in Mining

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The “things” mining

operations pit-to-port

Instruments and sensors

Integrated data platform, analysis and

data models

Connectivity, communications

and controllers

Decision support tools for prediction, optimization and

simulation

Continuous Optimisation

Page 8: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Why should the Mining Industry adopt new technologies?

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Since 2009 US coal companies have gone into bankruptcy & mines closed.

26

264 Capex fell to just in 2015 – half of the levels seen in 2012 & 2013.

Top 40 Mining companies suffered

their first collective net loss in history of

record high leverage of 46% and operating expenditure cuts of

$27b

$83b $69b

Source: PwC Mine 2016; Moody’s Corporate Default & Recovery Rates

Highest default rate in 2015 ever, for Mining & Metals companies,

with Oil & Gas companies at 6.5%

6.3%

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Why should the Mining Industry adopt new technologies?

Declining mining productivity fuels investment in “transformative” technology

Page 10: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Next Generation Automation: Integrated Pit-to-Port Operation

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Material Transport Model Accurately tracks the mass flow and properties through a system.

Material Influence Model Accurately predicts how the geometallurgical and physical properties of the feed material affect system performance.

CRUSHING GRINDING LEACHMINE

STOCKPILEGPS

THICKENER/CCDFLOTATION

THICKENER

TRANSPORT

CuCONCENTRATE

EW CuCathodeSTOCKPILING&WASTE

h

GPS

WASTE

GPS

SEAWATER TAILINGS

SX

THICKENER

Industry Innovation: Material Model: Tracking & Predicting Material Flows

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Industry Innovation: Prediction Based Controls & Optimisation

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Run a digital plant model based on custom set of control variables.

simulate

Powerful Training Tool

Operational Configuration Tool

Future: Operational and Financial KPIs

Predict

Decision-making Tool

Prediction-based Alerts

Optimised Operational and Financial KPIs

optimise Control Variables Continuous Recommendations/Set Points Automatically fed to the PLC.

Root Cause Analysis

Real Time

The user can run a digital plant model based on custom set of control variables.

Simulate

Powerful Training Tool

Operational Configuration Tool

Optimised Operational and Financial KPIs

Optimise Control Variable Recommendations/Set Points that are automatically fed back into the PLC.

Root Cause Analysis

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Hybrid Cloud Architecture

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USP •  Hybrid Cloud: Ability to support on

premise high availability and low latency control situations

•  Real time stream parsing of physical and machine learning model outputs

•  Horizontal scalability

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Accurate Physical and Geometallurgical Properties Unknown Material Properties

System View KPI Visualisation Limited Data Visualisation

Virtual Sensors Expensive Sensor CAPEX

System Wide Dynamic Predicted Set point Set Points Decided by Engineer/Process Owner

One Single Data Lake Manual Multi Source Data Gathering

Old World: New World:

System

Old World Emerging New World

Next Generation Automation: How is it different from today?

Page 15: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

User Case – Largest Copper Market in the world (Chile) & Mining Challenges

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Water Scarcity High Energy Cost

Declining Ore Grade Low Commodity Price

Page 16: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Case Study: Thickener Circuit Optimisation

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Benefits*: •  Increase underflow % solids •  Enhanced water recovery up to 10% •  Reduced flocculent consumption up to 5% •  Payback period: within 6 months

Typical Challenges •  Increased feed mineralogy variability •  Low underflow % solids & water

recovery •  High flocculent consumption

IntelliSense.io Technologies •  Accurately predict feed mineralogy -- geo-metallurgical & physical properties •  Provide optimal set point recommendations to the expert system •  Deploy optimisation simulator for diagnostic & training

* Actual values are client confidential data

Minera Centinela Characteristics •  105,000 ton of Copper processed per day •  Copper and Gold Mine, one of the largest

in Latin America

Page 17: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Thickener Circuit Optimisation & Stability: Business Case

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Reduce Underflow % Solid Variance Impact of Reduced Variance + 0.6 % Solid

Note: Benefits analysis performed on thickener circuit historical data from June to August 2015

Enhanced Water Recovery

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User Types and Scenarios

Tailings / Process Control Engineer Thickener Operator Plant Manager

•  Real time visibility of circuit performance for root cause analysis

•  Calibrate circuit optimisation rules

•  Access to simple to use simulator for delivering training to the operators

•  Real time predicted geo-metallurgical and physical properties of the feed material for decision making

•  Executing Prediction based alerts (1 hour)

•  Tracking the impact of the changes to performance variable set points

•  Real time visibility of circuit performance financial perspective ($/tonne processed)

•  Access to Executive Level Benefit Tracking for Circuit Optimisation and ad hoc performance reports

•  Simulating the impact of changes to circuit design based on real time performance simulator

brains.app for Thickener Circuit : user scenarios

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brains.app for Thickener Circuit: Tailings and Process Control Engineer

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Circuit Optimisation Calibration Real Time Debottlenecking Dashboards Training Simulator

Input: Feed & Control Variables

Output: Thickener Performance (+1 hour)

Page 20: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

brains.app for Thickener Circuit: Thickener Operator

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Prediction Based Alerts Predicted Geo-Metallurgical Properties Optimised Control Variable Set Points

Historical

Real Time

Future Performance (+ 1 hour)

Alert: Predicted Underperformance

Recommend: Control Variable Set Points

Optimise: Improve Underflow % Solids

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brains.app for Thickener Circuit: Plant Management

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Executive Level Economic Dashboard Real Time Financial Performance Circuit Design Change Simulator

Real time visibility of circuit performance ($ / tonne processed)

Page 22: Global C4IR-1 MasterClass Cambridge - Bose Intellisense 2017

Questions and Answers

Thank you

Sam G. Bose CEO & Founder, IntelliSense.io

[email protected]

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