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March 6, 2025 - In New South Wales, Australia, there is a significant coal mining operation known for its contributions to both local and national economies.
Since its inception in 1998, this mine has become a leading producer of high-quality thermal coal for domestic and international markets.
This is partly down to its methods, with the mine employing open-cut mining techniques and has a comprehensive coal handling and preparation plant (CHPP) to ensure efficient coal processing.
Hitachi Digital Services helped the company in charge of this mine address several key manufacturing objectives through digital transformation.
The objectives: Boosting productivity: Striving to achieve world-class productivity standards by harnessing process data effectively Managing coal quality: Ensuring coal quality meets customer contracts while optimising coal blends for maximum yield and performance Data-driven decision making: Utilising data to monitor performance losses, identify bottlenecks, and swiftly address asset failures
By embracing technological advancements and harnessing the power of data, the mining company was able to significantly enhance operational efficiency, product quality and overall productivity, setting new benchmarks in the mining industry.
Hitachi Digital Services is the trusted partner of the mining company in this journey and Manufacturing Digital caught up with Adwait Sarnobat, Senior Manager to learn more.
How did the mining company decide on the solution to address these challenges?
We needed a solution that could integrate seamlessly with our existing technology and systems and enhance our ability to analyse data in real time.
The partnership between Hitachi and the mining company aims to leverage digital technology to enhance operational efficiency, streamline processes and optimise performance.
By integrating HDS’s event management, Lumada Manufacturing Insights, Pentaho Data Integration and the Hitachi Unified Compute Platform Hyperconverged (UCP HC), Hitachi enabled the company to monitor and analyse critical operational metrics in near real time, facilitating prompt decision-making and proactive management that would enable manufacturing challenges to be addressed.
What were the key components of the Hitachi Digital Services solution implemented at the mining company?
Hitachi Digital Services has pioneered a range of innovative solutions that span the entire value chain, from drilling the coal, storing it, washing it all the way to train loading.
These solutions are now utilised by all key stakeholders within the company.
They integrate advanced technologies, such as machine learning, to identify anomalies in process data and predict overloading conditions in the thickener process.
The Digital Twin solution virtualises the entire operation, providing end-to-end traceability. Additionally, data patterns and trends are analysed through Grafana Dashboards, while real-time alerting is managed through event management systems.
Customised solutions address specific operational challenges, including managing crib breaks, service brakes and identifying bad patches, significantly enhancing efficiency and quality control.
What outcomes have resulted from implementing the Hitachi Digital Services solution?
Hitachi Solutions employs a robust value capture methodology that meticulously tracks both monetary and non-monetary benefits, providing clear visibility on ROI.
At the mining company, we are highly focused on the returns we get from our IT investments.
Our ROI-driven solutions typically break even within two years and our solutions also enhance process automation and KPI accuracy.
Notable solutions include service brake monitoring, which has significantly reduced brake application events and safety concerns and thickener rake overloading prevention, which averts major breakdowns.
Customised dashboards identify bottlenecks, preventing throughput loss, while coal tracking ensures yield targets are consistently met.
How has the implementation of this solution impacted the mining company’s overall operations?
Hitachi's digital services have significantly improved the team's understanding of plant operations under varying conditions.
Through comprehensive data analysis and visualisation, the team can identify patterns, predict potential issues and implement corrective measures to ensure optimal performance.
This has led to improved efficiency, reduced downtime and enhanced overall productivity of the plant.
Furthermore, the near real-time insights have empowered the company’s management to make informed decisions, optimise resource allocation and enhance safety protocols.
The collaboration has fostered a culture of continuous improvement, driving innovation and excellence across the mine's operations.
What future plans does the mining company have in light of these improvements?
As the mine evolves, the partnership with Hitachi Digital Services is poised to play a critical role in its growth and success.
The integration of advanced digital technology and data-driven insights will continue to uncover new opportunities, drive operational excellence and reinforce the company’s position as a leader in the coal mining industry. |
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