Transforming Legacy Systems
Enhancing Operational Stability at a North American Smelter
- Location: North America
Background and context
This North American mineral processing operation is one of the world’s largest integrated copper mining, smelting, and refining facilities. Its activities span the entire copper production process, from mining to producing high-purity copper cathodes, gold, silver, and molybdenum as by-products.
The operation is known for its focus on sustainability, including renewable energy investments and pollution reduction. However, with systems dating back to the late 1990s, some critical infrastructure at the operation required modernization to meet today’s operational and reliability standards.
The challenge
This smelter’s advanced control system for the flash-converting furnace relied on outdated hardware and unsupported software. The system was running into obsolescence, posing a risk of outages and interruptions to the copper production process.
Key challenges included:
- Hardware limitations: The system was running on a standalone Windows NT computer.
- Software obsolescence: The application was built and is running on legacy systems that are no longer supported.
- Data management issues: The system relied on Excel models and lab assay data that required integration into modern environments. Additionally, the client sought to transition control room operations to the Distributed Control System (DCS), eliminating the need for operators to interact with the standalone systems.
Mipac's approach
Mipac’s expertise in copper processing and automation enabled the team to anticipate challenges and craft a robust solution. The project was designed to ensure seamless migration and integration while maintaining operational continuity.
Key steps in the approach included:
- Platform modernization: Transitioning from a legacy platform to modern infrastructure within the process control network.
- Software upgrade: Implemented the application in.NET, ensuring compatibility with modern systems while preserving the Excel-based calculations integral to the workflows.
- DCS integration: Creating an operator interface within the DCS to streamline interactions and reduce reliance on the standalone application.
Overcoming challenges
Initial plans to migrate all components into the DCS were not feasible due to:
- The complexity of Excel-based calculations.
- Limitations in transferring historical lab assay data.
Mipac worked closely with the client to reach a practical compromise:
- Excel files were retained and updated to run on the latest version of Excel.
- Only the most recent five lab assays were made available to operators through the DCS.
Execution
The project followed a phased approach over two years:
- Assessment and planning: Evaluating the legacy system and identifying migration priorities.
- Development: Building the application using modern programming languages and infrastructure.
- Testing and validation: Conducting reviews with the client to ensure accuracy and functionality.
- Deployment: Rolling out the updated system and supporting operators in adjusting to the new interface.
Across the extended project delivery timeline Mipac maintained a focus on quality, ensuring a like-for-like replacement to prevent operational disruptions.
Results and outcomes
Improved reliability
Migrating to modern infrastructure reduced the risk of system outages.
Enhanced operator efficiency
Transitioning to a DCS-integrated interface simplified operations and minimized errors in setpoint transfer.
Maintained accuracy
The updated system matched the performance of the legacy system, ensuring consistent results.
Impactful improvements
- The application now runs on supported hardware within a virtualized server environment.
- Operators interact exclusively with the DCS, streamlining workflows.
- Risk of operational downtime due to hardware or software failures has significantly diminished.
Long-term value
The new system provides a future-proof foundation for this smelting operation, aligning with the company’s sustainability and operational goals. By addressing legacy challenges, Mipac has positioned the operation for further enhancements and scalability.
Advice to industry
For mining operations grappling with legacy systems, Mipac recommends:
Prioritizing modernization to mitigate risks from obsolete hardware and software
Engaging experienced automation partners who understand industry-specific challenges
Focusing on like-for-like replacements to ensure operational continuity
Conclusion
Mipac’s collaborative approach and technical expertise enabled this smelter to overcome complex legacy system challenges, delivering a reliable, future-ready solution. This project underscores Mipac’s role as a trusted partner for mining operations worldwide.
Mipac's edge
This project demonstrates Mipac’s unparalleled expertise in copper processing automation and modernization. With decades of experience, Mipac anticipates challenges and delivers tailored solutions, ensuring seamless integration and operational stability.
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