Executive Network
Click Here, Learn More
Edgar Cosslo
Senior Electrical Engineer, Rio Tinto and Resolution Copper Mining , Resolution Copper
The Resolution Copper project is a proposed underground mine 60 miles east of Phoenix, Arizona in an area called the copper Triangle where mining has been occurring for over 100 years. The ore deposit lies nearly 7,000 feet below the earth’s surface and is in the footprint of the historic Magma Copper Mine. It represents one of the most significant undeveloped copper deposits today. The mine has the potential to supply nearly 25% of US copper demand, thousands of jobs and billions in economic impact over a 60-year life.
Supernova Award Category:
The Problem:
The Resolution Copper Project is a joint venture between Rio Tinto and BHP. In line with Rio Tinto’s carbon reduction goals, the project wanted to look at ways to increase energy efficiency and improve the existing ventilation and cooling system for the underground workings.
The Solution:
Resolution Copper recognized that the existing ventilation and chilling systems could be upgraded to improve efficiency and reduce power use and identified the need for advanced automation and control technologies to improve its sustainability approach. They chose PowerFlex® Variable Frequency Drives (VFDs) by Rockwell Automation to optimize the efficiency of the ventilation and cooling systems and PlantPAx® Distributed Control System by Rockwell Automation to improve water management.
The Results:
The implementation of PowerFlex VFDs and adjustments to the glycol concentration in the cooling systems have improved the efficiency and performance of Resolution Copper's cooling systems. With VFDs, the mine can mitigate the electricity demand during the initial upsurge cycle, significantly reducing energy consumption.
The multiple stage water management system has significantly changed the way Resolution Copper manages water collection and pumping. By recycling the water as potable water and providing it to irrigation districts for agricultural use, Resolution Copper has established a sustainable water management practice that serves as a model for other mining operations and puts water to beneficial use.
The implementation of Rockwell Automation's PlantPAx® Distributed Control System has provided Resolution Copper with a reliable and robust backbone for managing their underground water management system. This system connects process, discrete, power, information and safety control into one plant-wide infrastructure, enabling Resolution Copper to efficiently manage and monitor all aspects of the operation.
Metrics:
After implementing the solutions, Resolution Copper saw a 5% increase in system efficiency and a 10% decrease in energy usage, amounting to $1 million in annual savings.
The Technology:
Resolution Copper also selected Rockwell Automation’s Studio 5000 Logix Designer, FactoryTalk Historian, and ThinManager Software to implement this project.
Disruptive Factor:
As the demand for copper continues to increase, particularly with the rise of electric vehicles, new copper supply will be needed to keep pace with demand. The Resolution Copper Project has the potential to supply nearly 25% of US copper demand once fully operational. The adoption of PlantPAx® Distributed Control System and PowerFlex® VFDs has improved the current mine’s efficiency, reliability and safety – showcasing the feasibility and benefits of sustainable mining practices and paving the way for future advancements in the industry.
Shining Moment:
The PlantPAx® Distributed Control System and PowerFlex® VFDs worked so well that we are now inspired to see how we can allocate and expand this type of innovative thinking across other areas of the underground and surface operations now and into the future.
About Resolution Copper
The Resolution Copper project is a proposed underground mine 60 miles east of Phoenix, Arizona, near the town of Superior. The project is a joint venture owned by Rio Tinto (55%) and BHP (45%). The mine has the potential to supply nearly 25% of US copper demand from a Brownfield expansion of an existing underground mine.
