Mining company to automate nickel recovery plant

Emerson has been chosen by Inco, the world's second largest producer of nickel, to automate a 1/100th scale demonstration processing plant currently under construction in Argentia, Newfoundland

Emerson Process Management has been chosen by Inco Limited, of Toronto, the world's second largest producer of nickel, to automate a 1/100th scale demonstration processing plant currently under construction in Argentia, Newfoundland.

The Argentia plant is being built to demonstrate the technical and economic validity of Inco hydrometallurgy (Hydromet) technology to process nickel concentrate.

In the event that the hydrometallurgical technology proves successful, a full-scale commercial plant using this technology will be built by the end of 2011.

The Argentia demonstration plant will process nickel concentrate produced at a mine and concentrator located at Voisey's Bay in northern Labrador.

Voisey's Bay Nickel Company (VBNC), a wholly owned subsidiary of Inco, is responsible for the development of the mine and concentrator, as well as processing facilities on the Island of Newfoundland.

The project includes installing Emerson PlantWeb digital plant architecture to automate the new demonstration plant.

This digital approach uses an open, standards-based FOUNDATION fieldbus network to connect intelligent field devices and the Emerson DeltaV digital automation system.

PlantWeb diagnostics in the intelligent field devices will continuously monitor the health of the process, instruments, and equipment, and will inform personnel of any issues that need attention, plus will provide guidance for operators and maintenance staff to address potential problems before they diminish process performance or cause shutdowns.

The PlantWeb architecture of the new demonstration plant has more than 100 pH measurement loops that are critical to plant throughput and performance.

To achieve the required precise pH control, the advanced Rosemount Analytical Xmt transmitters will be installed: the built-in digital diagnostics will allow continuous monitoring of the instrumentation and process health.

Rosemount Analytical TUpH sensors with Silcore technology from Emerson will be installed in critical loops to withstand the very harsh chemical environments and deliver greatest reliability.

The digital PlantWeb network will also include Rosemount pressure and temperature transmitters and magnetic flow meters, Fisher control valves with FIELDVUE digital valve controllers, and Rosemount Analytical conductivity measurement instruments.

AMS Suite: Intelligent Device Manager asset optimisation software will gather and utilise diagnostic information from the smart field devices.

The AMS Device Manager also receives PlantWeb Alerts that are generated when issues arise.

The Alerts inform of impending situations, and give guidance to operators and maintenance personnel to help them avoid process interruptions and maintain a high level of plant availability.

"The demonstration facility is the precursor of a commercial plant," said John Casson of VBNC.

"In addition to using PlantWeb in the plant, we are using the DeltaV system at the mine and concentrator at Voisey's Bay.

The PlantWeb architecture will allow us to save substantially in installation and commissioning costs while enhancing diagnostics and making the entire system easier to configure, commission, and maintain.

The demonstration facility is being built on an extremely fast track," continued Casson.

"We are supported by substantial technical assistance from Lakeside Process Controls in Toronto and Laurentide Controls, Montreal, the Emerson local business partners in eastern Canada.

Two companies from Newfoundland and Labrador, Sea Systems Inc and Avalon Controls and Instrumentation, are also providing key talent and services to the project.

Lakeside serves as a single point of contact for VBNC and SGE Hatch, the process and automation consultant in St John's.

Laurentide, through Avalon Controls and Instrumentation, is managing the automation supply contracts for the demonstration plant and providing on-site liaison with SGE Hatch".

Because this is a new process, built for research and to optimise the metal yield, Inco is utilising state-of-the-art tools, including PlantWeb with fieldbus digital instrumentation and the DeltaV system, that offers such advanced control solutions as fuzzy logic, neural networks, and multivariable process control.

"One of the key deliverables from the demonstration plant is a comprehensive and accurate record of all process and production parameters, including instrumentation performance data, as the plant moves through its operational phases," Casson said.

"The DeltaV system, in conjunction with the PlantWeb, DeviceNet, AS-i, and fieldbus technologies, reliably and cost effectively serves this need, while allowing integration with Level 2 and above systems".

"We are gratified with the Inco selection of PlantWeb advanced functionality and technology to automate its valuable new mineral recovery technology," said John Berra, president of Emerson Process Management.

"We're confident that the proven innovation and efficiency of PlantWeb will add value to the new Hydromet mineral processing approach.".

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