Mining Solutions

The
connected
mine
Rockwell Automation® solutions for mining
BEGIN
The world
needs mining
THE WORLD IS SEEING INCREDIBLE CHANGES
that require resource-intensive goods of all sorts.
Overall population is growing and shifting to urban
areas. The middle class is expanding, infrastructure
development is increasing and with this growth comes
a need for resources. Metals like iron, copper, aluminum
and nickel will come with a much higher demand. In
addition, the quest for a less carbon-intensive future
has spurred growth in electric vehicles – and lithium,
magnesium, cobalt and other minerals used in battery
production. Likewise, bigger and better energy storage
batteries are flooding the marketplace to support wind,
solar and other clean sources of power.
Our world is changing before our eyes, and these

changes must be met through the support of mining.
The connected mine Increase operational Mine-to-market Modernize and empower Design, build and upgrade
PG 2 efficiency visibility your workforce with confidence 2
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Strong market fundamentals
are in place, but the mining
industry faces headwinds.
MARKET VOLATILITY
IS THE NEW NORMAL
Even with projections of higher demand, the
mining industry is still facing many challenges.
Market volatility and uncertainties directly
impact business - which adds complexity
to long-term planning for new projects or
upgrades to existing sites.
Ever-evolving legal and governance

regulations are keeping mining companies
on their toes. Not to mention the constant
need to satisfy shareholders while working in
partnership with stakeholders to earn their
social license to operate.
Optimizing operations and assets is critical

and bridging the skills gaps and addressing the
changing workforce demographics is key for
companies to stay afloat.
By focusing on and putting a plan in place

to address these key areas, many other
challenges can be resolved as a result.
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Operational
challenges
Mining is, by nature, complex. And it’s getting more complex as
companies are forced to dig deeper and go father to access better
ore grades.
Mining companies continue to be challenged with identifying process

efficiencies, keeping equipment operating properly, effectively using
water and energy, and ensuring workers stay safe.
Controlling these variables is crucial to remaining profitable, and each

one can be devastating to a mining company if a misstep occurs.
• PROCESS EFFICIENCY (General costs pressures, grade decline)
• COST (Equipment maintenance)

More than 60% of the
• ACCESS (Effective use of land, energy and water) total mine workforce can be
almost exclusively focused
• WORKER HEALTH & SAFETY on servicing or repairing
assets in the mine.
• ENVIRONMENTAL IMPACT
Source: Miningglobal.com
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The
workplace
challenge
How to attract and retain the
next generation of workers 75 % 41 %
of millennials prefer
Mining companies are working with a rapidly of the workforce will communicating
be millennials by 2025. electronically
changing workforce. With interest in mining
dwindling and a boom in technological knowledge, at work.
mining companies are required to up their game
to attract, train and keep the best talent.
mining engineering enrollments at

University of NSW in 2017, the lowest in 40 years
Source: Forbes; PwC; Chairman Jake Klein (Evolution Mining)
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DIGITAL TRANSFORMATION PROVIDES A MAJOR OPPORTUNITY
to address industry challenges. The projected realized value from digital
transformation initiatives from 2016 to 2025 could equal $320 billion USD,
according to the World Economic Forum. There is broad consensus across
the industry that digital technologies are key to better performing mines.
Opportunity
However, many challenges stand in the way to true digital transformation.
Without a clear strategy in place that includes a business case and expected
ROI, many companies jump in head first without a picture of what they’re hoping
in digital
to achieve. Some companies cannot evolve due to their legacy technology
infrastructure or their workforce lacks the skills necessary to adapt to the
change. Or maybe the challenges lie within company culture, upfront funding or
transformation
the ability to keep up with changing technology.
The truth is, 85% of big data projects fail today as a result of one or more
of these challenges.* But there are ways to anticipate and overcome these
challenges to continue on your journey to digital transformation.
*Source: Gartner
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Why Rockwell Automation?
Your journey toward achieving the connected mine is unique. Rockwell Automation
has the capabilities and experience to support your digital transformation, no
matter where you stand in your journey. Our people and partnerships are at the
heart of what we have to offer:
Technology leadership in process

control and analytics
The mining, IT and An unmatched

automation expertise network of
you expect partners
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HOW DO WE OVERCOME THESE CHALLENGES?
Rockwell Automation® helps miners plan their digital transformation journey from
start to finish. Proper planning and project management allows challenges to be
identified and addressed in the early stages of a project - before the entire project is
derailed. Adhering to a project plan keeps your digital transformation initiatives on
budget and on schedule.
1. ASSESS
Evaluate and understand the status of your mine.
2. STRATEGIZE
Develop a future vision of what you would like to achieve through digital transformation.
3. IDENTIFY OPPORTUNITY
List problems, potential solutions and associated technologies that can help you on your journey.
4.DOCUMENT
Draft a business case and define quick wins and ROI you expect to achieve.
5. COMMIT
Select cases and define your targets, teams and partners that will help you on this journey.
6. PILOT
Test and evaluate the results through the initial stages of implementation.
7. SCALE
Multiply and scale the successes you are seeing across your target area.
8. REVIEW
Revise the project and assess results based on the initial goals of your project.
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The connected mine
Integrated systems and scalable analytics
enable mine-to-market visibility and allow
for better decision-making.
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The connected mine
End-to-end architecture and systems integration
Enterprise and ERP

business applications
Third party applications & systems IoT platform / Analytics Remote monitoring
and visualization
Supply chain Process Asset

simulation optimization performance
IoT gateways Integrated process control and power
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The connected mine
Actual equipment
DIGITAL TWIN CONCEPT

Enabling reduced capex and opex optimization
DIGITAL TWIN FEATURES

Mechanical CAD Electrical CAD
Process simulation Mathematical modeling
Virtual commissioning Mobility
Virtual operation Operator training
DIGITAL TWIN BENEFITS

Better prototyping Validate your strategies
Easily design and build the Optimize throughput with simple,
next generation of equipment real-time 3D simulation of
with confidence. complex dynamic processes.
Virtual commissioning Operator training

Design, test, validate and Reduce risk and improve
commission systems before operations by training workforce
they are put into service. in a safe virtual environment.
Digital twin
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Increase
operational efficiency
Tested and validated architectures and
dedicated functionalities for mining
operations help you get the most out of
your process and equipment, and improve
your overall productivity.
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MINE
EXTRACTION EQUIPMENT
Powering and enabling analytics
for mobile equipment
Equipment reliability is dependent on the
drive system and with remote monitoring and
diagnostics available, you can keep tabs on
your equipment from anywhere. We offer high-
performance drive solutions for shovels and
draglines, including technology for extreme
conditions and high availability, providing data
acquisition and telemetry.
MINE
CRUSHER AUTOMATION
Improved control and monitoring
for crushers
By integrating process and motor control,
you can get the most from your equipment —
reducing mechanical stress, causing fewer
disturbances, and lowering maintenance
costs — all while maximizing performance,
maintaining production consistency, and
saving energy.
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PROCESSING PLANT
MILL AND CONCENTRATION
Solutions that help you meet your
plant objectives
An integrated control system reduces
engineering risks and is easier to operate,
maintain and modify, and delivers a unified
view of the typical processing plant areas.
Seamless integration between critical areas
of your plant allow you to connect process,
discrete, power, information, and safety
control into one plant-wide infrastructure.
This provides an integrated environment for
configuration, operation and maintenance.
PROCESSING PLANT
METAL REFINING
AND PYROMETALLURGY
High performance systems for process
and energy intensive applications
The PlantPAx® system provides a modern
approach to distributed control for metal refining
applications. An open standards, high-availability
DCS means more flexibility and efficiency for
complex and large metal processing applications,
and redundancy across systems all while
operating on an integrated architecture.
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PROCESSING PLANT
DEDICATED APPLICATIONS
FOR MINING PROCESS CONTROL
Standardized methodology and
functionalities for mining controls
Standardized methodology and pre-engineered
content for control, monitoring, visualization,
alarms and reporting allows for the
multiplication of tested and validated best
practices across all sites. Libraries and
advanced functionalities have been developed
specifically for the mining industry.
PROCESSING PLANT
ADVANCED
PROCESS CONTROL
Reduce variability and stabilize
complex processes
Model Predictive Control (MPC) optimizes
complex processes and delivers more
throughput, better recovery and less variability
all while minimizing use of energy and reagents.
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MATERIAL HANDLING
CONVEYORS AND STACKER
RECLAIMERS
Information-enabled machines and
equipment deliver real-time performance
and operating data
Lower engineering costs, improve machine
efficiency and reduce maintenance costs by
using integrated architectures for conveyor
systems and stacker reclaimers with remote
monitoring from anywhere, anytime.
MATERIAL HANDLING
HOISTING
Productivity and safety for hoisting can
be a critical part of an underground
mine, demanding solutions that address
productivity without risking safety
A combination of automation, safety solutions,
and intelligent motor control delivers safer, more
reliable, high-performing hoisting systems.
We partner with top mechanical suppliers to

deliver best-in-class hoist solutions.
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UTILITIES
MINE ELECTRIFICATION
Intelligent packaged power; single
supplier, single backbone
Reduce downtime and improve safety by
integrating process controls with power
distribution, substation automation and
motor management.
UTILITIES
SUPPORT AREAS
Improved control and visibility across
your entire mine site
We provide solutions and integrated
architectures for supporting areas, such
as ventilation, compressor systems,
pumping systems, water telemetry and fuel
management for mining.
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Mine-to-market
visibility enables
better business
decisions
When you collect, aggregate and analyze
data across operations, you can spot
trends and interdependencies that are
missed when data lives in silos. With this
type of information, you can make more
informed decisions.
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The power
of analytics
ONE MAJOR CHALLENGE mining companies face
is disconnected and siloed information. It’s a constant
struggle to find ways to aggregate and contextualize
information from various areas of the business to
enable better, more holistic decision-making.
FactoryTalk® InnovationSuite, powered by PTC

enables data collection and aggregation, surfaces
contextualized information so you can take action,
and offers powerful visualization tools that bring data
to life and enable better decision-making.
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Mine-to-market integration
Our FactoryTalk® solution allows mining companies to collect data from nearly any
source within the enterprise and quickly build applications and decision tools.
Analytics platform
Mining technical
applications Remote monitoring
Metrics / Key performance indicators (KPIs)
Third-party Visualization
Downtime Inventory consolidation
applications
OEE Quality
Human interfaces
Supply chain
management Historian
Embedded
analytics
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The most
important
data at your
fingertips
Integrate information
from any data source
Track production
and inventories
Benchmark different
mines and operations
Contextualize and display KPIs

(OEE, downtime, energy and water consumption)
Create powerful mash-ups with any

relevant information for the business
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Supply chain
simulation
Mining supply chains are an intricate sequence of material
movements and processes, and there are several potential
combinations of material movements across the value chain —
extraction, conveyance, stockpiles, processing plant, rail and port.
Simulation tools can help mining companies analyze potential

changes to their operations and supply chains, and even
incorporate the impact of external factors like weather, market
demand and commodity prices.
Our Arena® solution enables discrete event modeling, the process

of depicting the behavior of a complex system as a series of well-
defined events. This works well in virtually any process where
there is variability, constrained or limited resources, or complex
system interactions.
Discrete event simulation allows users to analyze the behavior of

a process or system over time. Users can ask “why” or “what if”
questions, and test designs or changes to processes or systems
without any financial implications.
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Modernize and
empower your
workforce
New technologies are expanding
human possibility. Incorporating these
technologies into your worker’s daily lives
can ease workforce transitions, increase
worker productivity, foster collaboration,
and provide a safer, more engaging
environment for all employees.
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WORKER SAFETY AND EFFICIENCY Our mobility solutions extend
MOBILE REAL-TIME visualization and real-time
INFORMATION decision capabilities.
By nature, mining operations are spread
out geographically. Field workers often find
themselves servicing or operating equipment
without a direct view into how the specific
piece of equipment is performing. This lack
of visibility and information can reduce
productivity and result in unsafe operations.
Our mobility solutions extend visualization and

real-time decision capabilities to browser-
based remote users including mobile devices.
With on-demand, real-time access from
anywhere, every team member benefits from
this visibility into the mine.
57
greater employee
%
productivity/efficiency
possible with mobile
technology
Source: Motorola / mobientech.com
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WORKER SAFETY AND EFFICIENCY
AUGMENTED REALITY
Superimpose digital information onto real
objects or equipment, providing field personnel
with real-time information in context of the
true process. This technology helps mining
companies enable remote expert advice
for equipment maintenance and augment
the training process to create customized,
memorable instruction for new workers.
SEE THE RESULTS
• Better employee productivity

• Safer operations
• Remote collaboration
• Expert advice
51 %
of respondents said that their
company had already seen a
measurable ROI when it came
to using AR for employee
training / knowledge
transfer
Source: PTC / IDC
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Design, build
and upgrade
with confidence
New projects and upgrades can be risky to
undertake. Reduce your risk of overspend
and delays with better up-front planning,
fewer vendors, and tested project
methodology and architectures.
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Projects lifecycle support
Reducing risk and creating value throughout your production lifecycle
Feasibility & Front end

Design & Installation & Operation & Upgrades &
conceptual engineering
engineering commissioning maintenance migrations
studies & design
• Feasibility studies • Information, control, • Design & • Installation • Remote system • System audits
power, safety implementation management monitoring
• Conceptual design • Obsolescence risk
• Process optimization • Construction, • Start up / • Service agreements mitigation
• Consulting services
fabrication commissioning
• Instrumentation • On-site engineering • Hardware / software
• Workforce readiness
• Testing (FAT) • Training upgrades
• Electrical • Asset management
• Training • Documentation • DCS / control &
• Packaged equipment • Reliability
safety system
• Network and security • Parts management
migration
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Cybersecurity
Solutions and services
VALIDATED SOLUTIONS / ARCHITECTURES

Comprised of a collection of Cisco® and Rockwell Automation® validated
designs, our architectures are tested for performance, availability,
repeatability, scalability and security. This means you get fast, tested
access to ‘future-ready’ network design.
CYBERSECURITY SERVICES
From assessment to a response plan deployment, we can provide
a full lifecycle service focused on industrial security. Our experts
understand how to securely bring together IT and OT, and help secure
your infrastructure, protect assets, and maintain network availability.
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A proactive approach to
industrial cyber security
Attack continuum
BEFORE DURING AFTER
IDENTIFY & PROTECT DETECT RESPOND & RECOVER
Asset inventory services Real-time threat detection services Backup and recovery solutions
Vulnerability and risk assessment Remote monitoring and administration services
Qualified patch management Incident handling and response
Industrial control system security Incident response and disaster recovery planning services
zone and IDMX segmentation
Industrial security
countermeasure deployment
BUILD A SECURE, ROBUST, FUTURE-READY NETWORK FOR YOUR CONNECTED MINE
Assess Design Implement Validate Monitor
A holistic approach to help you design, deploy, and manage your network infrastructure
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BACK
Connect with us.
rockwellautomation.com
FactoryTalk and PartnerNetwork are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication MIN-BR004A-EN-P - May 2019 Copyright © 2019 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

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The

Our world is changing before our eyes, and these

Ever-evolving legal and governance

Optimizing operations and assets is critical

By focusing on and putting a plan in place

Mining companies continue to be challenged with identifying process

Controlling these variables is crucial to remaining profitable, and each

• PROCESS EFFICIENCY (General costs pressures, grade decline)

• COST (Equipment maintenance)

mining engineering enrollments at

Source: Forbes; PwC; Chairman Jake Klein (Evolution Mining)

Technology leadership in process

The mining, IT and An unmatched

Enterprise and ERP

Supply chain Process Asset

IoT gateways Integrated process control and power

DIGITAL TWIN CONCEPT

DIGITAL TWIN FEATURES

DIGITAL TWIN BENEFITS

Virtual commissioning Operator training

We partner with top mechanical suppliers to

FactoryTalk® InnovationSuite, powered by PTC

Contextualize and display KPIs

Create powerful mash-ups with any

Simulation tools can help mining companies analyze potential

Our Arena® solution enables discrete event modeling, the process

Discrete event simulation allows users to analyze the behavior of

Our mobility solutions extend visualization and

Source: Motorola / mobientech.com

SEE THE RESULTS

• Better employee productivity

Source: PTC / IDC

Feasibility & Front end

VALIDATED SOLUTIONS / ARCHITECTURES

Vulnerability and risk assessment Remote monitoring and administration services

Qualified patch management Incident handling and response

BUILD A SECURE, ROBUST, FUTURE-READY NETWORK FOR YOUR CONNECTED MINE

Assess Design Implement Validate Monitor

Connect with us.

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