Exxaro and Wabtec bump up throughput at coal operation using Proficy CSense | Velotic
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Exxaro and Wabtec bump up throughput at coal operation using Proficy CSense

Learn how Exxaro and Wabtec increase throughput at their coal operation after implementing Proficy’s CSense with digital twin capabilities.

Case study
Company
Exxaro
Industry
Manufacturing & Digital Plant
Products
Proficy CSense, Predictive Analytics

Overview
10%
Increase in Throughput
+98%
Utilization Since Commissioning
6 Month Budgeted Cycle
Successful POC
About Exxaro

About Exxaro

Since their formation in 2006, Exxaro Resources Limited has grown to become one of the largest and foremost black-empowered coal and heavy mineral companies in South Africa, with other business interests around the world in Europe, the United States of America, and Australia. Our asset portfolio includes coal operations and investments in iron ore, pigment manufacturing, renewable energy (wind), and residual base metals. In 2019, Exxaro produced 45.6 million tonnes (Mt), reflecting contributions from our expanded flagship Grootegeluk mine. At 31 December 2019, the group had assets of R68.8 billion and a market capitalisation of R47 billion (US$3.3 billion).
Challenge

Challenge

Like many industries, coal processing is complex, and digital transformation provides an opportunity for improvement. The absence of advanced process controllers (APCs) in the coal processing industry led Exxaro to explore research into opportunities for improvement, particularly in the area of throughput.
Action

Action

With research showing that Exxaro could expect a 5% gain in throughput, the company worked with Wabtec to implement Advanced Process Control, leveraging Velotic’s Proficy CSense and process digital twin technology, at its GG45 process plant. Following success, the team implemented two more APC projects and explored a skills’ transfer process to Exxaro engineers to maximize use of the solution.
Outcomes

Outcomes
  • Nearly 10% gain in throughput
  • Utilization higher than 98% (from commissioning to date)
  • Proof of concept completed within 6-month budgeted cycle
  • APC solution is now solely utilized to control the GG5 plant, including start-up, shutdown, and steady state conditions
  • Continued collaboration and continuous improvement
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