Real-time Filtration Analytics and Automatic Reporting

Project Overview

Industry

Mining and mineral processing industry

Challenge

The need for real-time analytics

An alternative to manual production, quality, and maintenance reporting was needed

Solution

Roxia SmartCube™

Roxia Malibu™

Benefits

  • Fast and low-cost IIoT-system implementation
  • Real-time view for pumps and dewatering equipment
  • Automated PDF reports for different personnel, including production, quality, and maintenance reports
  • Suitable user interface for different user groups, such as operators, maintenance workers and management level
  • Easy-to-use and interactive reporting tools
  • Automated alarms and notifications for process parameters, production deviations and maintenance needs
  • Possibility for online & remote troubleshooting
  • Better process analytic tools and filtration
  • 2 years of data storage
  • Huge expansion possibilities
  • High-level cyber security included

One of Roxia’s European customers with a long history in international mining and mineral processing decided to start an IIoT project together with us. The installation of the Roxia MalibuTM solution for a single hose pump in a gold mine located in Turkey enabled automatic reporting and filtration analytics in real-time.

The preliminary idea was to monitor pump performance and health, as it was a critical piece of equipment in gold processing. Roxia supplied all necessary hardware including a wide set of instrumentation, such as vibration, temperature, and pressure sensors. Those sensors were connected to the new Roxia SmartCube™ edge device, which analyses the data and transmits it to the Roxia Malibu Cloud system. The system and its customized user interface provided a good overview of the pump’s current status, performance, and maintenance needs – all in real-time, without the need to change any existing control infrastructure on site. The gained data is presented in a user-friendly format and the system can be accessed with a normal web browser or mobile phone.


Roxia’s Application Manager for Smart Solutions, Simo Rounela, is checking the first installation on site

Extension of use and integration of filter presses

After successful piloting, the customer decided to expand the already existing system. As Roxia is well known for dewatering and especially filtration technology, the next integration was concerning three horizontal, fast-action filter presses used in tailings dewatering. Those filters were already over 10 years old with original control panels and manufactured by another supplier.

The new system integration utilized the Roxia SmartCube™ Gateway, which was already used to collect all existing data these filters had in each of their control systems. One SmartCube™ was able to integrate all three filters with a single Ethernet cable and without any changes to the filter’s programmable logic controller (PLC) software. All filters remained in a running state through the integration process and on-site installation time was less than a normal workday.


                                                         Mapping all data points and designing the solutions

Easy SmartCube installation with remote support

The latest upgrade was concerning the fourth filter press used in the gold concentrate dewatering process. The project started at that time when due to the COVID-19 pandemic, traveling was restricted. But because the customer environment was already well known to our Roxia Automation Engineers, the new SmartCube installation was fully completed by the customer’s Automation Engineers, and it was done within one hour of work.


Malibu view for accessing real-time measurements – here with example data

Secured Data

Roxia Digital Services are secured by SSL/TLS encryption – the same technology used for e.g. internet banking. Hardware-based Virtual Private Networks (VPN) and physical firewalls isolate filter PLC from public networks. Roxia is using its own internet connection to send the data to the cloud. Roxia Smart Cube is configured as a read-only system, which means that our Smart Filtration tool cannot affect the filtration process in any way. No DCS (Distributed Control System) integration is needed, but it can be arranged upon request.

 

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If you have something on your mind, just let us know! We are more than happy to answer all your inquiries.

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Danie Groenewald

Area Sales Manager South Africa

+27 10 590 8374

Kauko Tanninen

President, Russia & CIS

+7985 226 14 91

Russell Beaumont

Senior Service Manager, Filters Australia

+61 408159305

Ettienne Joubert

Sales Engineer South Africa

+27 (0) 81 030 1015

Sun Lin

Area Sales Manager, General Manager China

+86 21 52679628

Lyle Henson

Environmental Technologies Sales Manager North America

+1 443 695 9510

Dan Stenglein

Sales Director North America

+1 667 500-2591

Ronald Gaspar

Technical Service Manager Peru, Colombia

+51 9 7973 5424

Robert Parks

Filter Sales Manager North America

+1 410 636 2250

Maureen Brown Briceño

Sales Manager South America

+56 9 7740 0878

Yury Beloborodko

Director, Filtration MMM & CEEC Russia & CIS

+7 921 959 46 20

Sergey Petukhov

Technical Director Russia & CIS

+7 495 726 57 41

Don Kitchen

Filter Spares Sales & Service Manager North America

+1-410-636 2250

Jesse Saira

Area Sales Manager Nordic and Baltic Countries

+358 44 276 2338

Dirk Otto

Sales Director Central Europe

+49 (0) 2102 420 707

Victor Ortega

Area Sales Manager Asia Pacific

+61 499 156 590

Juho Uusitalo

Area Sales Manager Eastern Europe

+358 40 680 4396

Kimmo Angeria

Head of Field Services, Roxia Automation

+358 400 104 977

Eduardo Paredes

Sales Director South America

+56 994 991 561

Markus Saloniemi

CEO, Roxia Automation

+358 40 571 9520

Fernando Henriquez

Sales Director Peru

+51956360887

Petri Kiljunen

Petri Kiljunen, Regional Director, Middle-East and Mediterranean

+971525252178