Automation System for Processing Tank Descale Rig with Advanced A.I. driven 3D radar and sensor technologies

The Challenge 

The rapidly evolving safety, commercial and cultural trends that affect manual activities in mining/minerals industries necessitates urgent development of automated solutions. 

Large processing tanks are used extensively in mining and minerals sites. These tanks often represent a critical path for production output. The ability to rapidly service this infrastructure when offline can deliver very significant productivity benefits. This is particularly relevant in Alumina plants where large volumes of scale are regularly required to be removed from tanks. 

Currently, there is no Automated solution for this activity globally and the current methodologies present with many safety, productivity, cost and workforce challenges. HSEQ incidents include physical injuries, falls from heights, chemical burns, heat stroke and exhaustion. Plant down-time, blasting activities and injuries represent the highest costs to industry. 

There are over 500 refineries, mines and plants globally using large diameter tanks that require high pressure blast cleaning. Automated blasting may also be applicable in the oil sector where over 2000 of plants exist.  

Proposed Solution 

TMT proposes that focussed R&D will allow the development and integration of new technologies to facilitate the operation of a High-Pressure Waterjet Blast Rig in an Autonomous manner whilst managing environment scanning, blast path programming, motion control, obstructions and blast methodologies. These technologies include; 

• Advanced 3D radars for the pre- and post-scanning of the tank, and the generation of the digital tank surfaces and renders. 

• Next generation combines radar technology and self-cleaning cameras for live wall scanning in a very low visibility, high noise environment during blasting. 

• A digital Simulated Environment showing the live environment data used by the Automation Program to generate the blast paths and strategies.  

• Critical sensors including force limit switches, inclinometers, industrial microphones, and position sensors will provide critical feedback to the automation suite.  

• Development of safety protocols and H.M.I. to allow the system to operate unmanned. 

Critically, an automated blast rig will also assist the mining and mineral sector to address rapidly evolving, employee diversity regulatory requirements. 

Proposed Benefits to WA 

This project is funded under the MRIWA Mining Technology, Equipment and Services (METS) Innovation Program. It demonstrates industry-led research which aims to develop new products, companies and markets for the Western Australian mining and minerals sector.  

The benefits for Western Australia under this project will be realised in three main ways; 

• Direct benefit to Mining and Mineral Processing facility Operators 

• Benefit to WA Employment, Industry Viability, Workforce diversity and Safety. 

• Benefits to WA Technology based institutions, companies and manufacturers. 

Productivity offered through automation will directly benefit WA’s industry viability. With a high demand for minerals such as Alumina, plant down time has been identified as the major area of opportunity. The proposed Automation suite will directly improve tank blasting activities which is the critical path for returning plant trains to operation.