Innovative solutions to help businesses in the mining and process industries increase efficiency, reduce cost, and improve profits, backed by qualified process and metallurgical engineers.
// 01 · APC
Advanced Process Control
Maximise profits, stabilise plants.
Gain control of your processes
APC maximises profits by stabilising plant processes and continuously calculating optimal setpoints using technologies such as MPC, multivariable control, process modeling & simulation, and online optimisation algorithms.
Unlock maximum potential
The objective of advanced process control is to push the plant as close as possible to the operating region or limit where maximum potential profits are realised. A two-step approach is followed: first the process is stabilised, then optimal setpoints are continuously calculated to keep it in an optimal state. Numerous technologies are utilised, including model predictive control (MPC), multivariable control, process modeling and simulation, and online optimisation algorithms.
Blue Nickel has successfully integrated APC solutions into flotation, milling, crushing, kilns, autoclave and abatement equipment, hot gas generators, as well as drying and evaporating processes. These solutions continue to create significant value for our clients today.
Dynamic and steady-state modeling & simulations determine optimal operating regimes. Implemented recommendations lead to significant performance improvement.
Gain efficiencies with process optimisation and data mining
When investigating process performance, it's common to combine data mining and analysis with sound process engineering principles. This helps ensure that the process is working at maximum efficiency and that any areas where improvements can be made are identified. Many factors are considered when assessing performance: stability, the role of the operator, instrumentation, control system logic, equipment efficiencies, metallurgical performance and operational cost.
One way to determine the optimal operating regime is through dynamic and steady-state modeling and simulations. These methods can predict process performance under different conditions and identify the best settings for each variable.
The recommendations from these studies can result in significant improvements in process performance, reducing operational cost, increasing efficiency, and improving overall performance.
Blue Nickel provides a customised solution that meets all data storage and management needs. We deliver a single integrated system with one tag list, one data source and one standard web interface. With data access being a core process in all mining and process industries, our solutions make access and interaction seamless to reduce cost and improve profits.
Solution benefits
Storage for large amounts of process and time series data, with unlimited tag lists
Rebuilding data based on interpolation of existing data
Web interface for manual data like log sheets
Web service to access data programmatically
Excel add-in
Transformation and analysis of data, real-time and offline, are central to what we do. To assist with this, we have developed powerful software tools that seamlessly integrate with any database or control system to perform complex data manipulation tasks in real time.
Tools such as the Phoenix Historian log all process data from PLC or SCADA indefinitely. Data from elsewhere (LIMS, weighbridge databases) can easily be pulled into the historian so all data is available from one central location. Phoenix Historian gathers, compresses and archives the data for statistical calculations and analysis. Access is made easy through DART and Excel.
Only once you know there is a problem can you fix it. Our reporting solutions integrate the latest technologies to roll up large quantities of process data in meaningful summaries that are easily accessible. Sub-optimal process or equipment performance is rapidly identified through state-of-the-art reporting and dashboard interfaces.
Our reporting solutions include production reporting, cell phone reporting, control loop performance monitoring, process stability analysis, environmental monitoring, downtime analysis and instrumentation measurement validation.
Solution benefits
Access data from any source
Visualise data online and offline on a dashboard interface
Summarised reporting of data tags in customised time trends
Event or interval-based reporting
Measurement limits and threshold triggers
Monitoring of as many tags as you want
Accurate insight into process KPIs
Detection and prediction of weak spots in production
Evaluation of overall equipment effectiveness and operational cost
Automated monitoring of hundreds of PID control loops
Identification of poor loop performance, sub-optimal tuning, faulty valves, and malfunctioning instruments
Useful information is presented in tables and graphs delivered by automated emails to PCs and mobile devices through messaging apps, SMS and MMS. The result: accurate process information for the right decisions, uniquely designed to suit your monitoring and reporting needs.
// FROM FOUNDATION TO TRANSFORMATION · LAYER BY LAYER
Transform your business layer by layer
Many companies today are rushing to transform their operations via Digital Transformation (DX) but do not fully understand what DX is or how to incorporate it into their business model.
Blue Nickel has been providing services and products to digitalise business processes for years, and understands that transformation does not happen overnight. To bring your business into the digital age, change should happen at the lower-level services first and make its way up the system, layer by layer, transforming your operation into a digital empire.
We offer operator training simulators with dynamic process models, control system design and validation, advanced process control training, metallurgical services and Excel training. Our training programmes are tailored to your operation and team · giving operators a comprehensive understanding of plant operations through dynamic simulation.
Operator training simulators with dynamic process models
Nine purpose-built software products for modern process operations.
Request a demo
See it in action, on a plant like yours.
Tell us which product you're interested in and a little about your operation. We'll set up a personalised walkthrough using a similar plant to your own, so you can see exactly how it performs in production.