In the rapidly evolving energy sector, coal remains a critical resource. However, the traditional methods of coal washing have often faced challenges like inefficiency, high operational costs, and inconsistent product quality. Digitalization in coal washery operations emerges as a transformative solution, driving cost optimization and significantly improving productivity.
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One of the biggest mining companies in India wanted to implement Industrial IoT across one of their sites. The primary objective was to focus on digitizing coal washery so as to measure the real-time performance of assets. With existing layers of automation, the stakeholders were unable to perform the granular analytics of the assets quickly and below were the challenges faced:
Carbynetech assessed use-cases to quickly draw out the features, user stories and wireframes with the manufacturing experience of similar domain companies. Our engineering services and technology team studied the automation level at the coal washery and configured OPC software for data acquisition. The data was acquired from the existing PLC and sensor system along with tags mapped in the OPC. The Big Data Platform chosen was Splunk Enterprise because of its lower operating cost. Technically, the same solution can be deployed on Microsoft Azure and AWS.
The solution covered the below modules.
Asset availability increased by 6 – 8% which resulted in soft and hard savings
Data insights helped identify the hidden opportunities -idle running of assets without load
Mobile on the go – analytics- ease of data access
An immediate improvement in asset performance, real-time asset visibility and feature rich analytics which demonstrated the necessary steps to be undertaken by the washer operations team. It also led to significant savings with respect to idle energy consumption and machine stoppages.