As a leader in technologies driving the digital transformation of industries, ABB is showcasing a range of its solutions serving diverse sectors at Electra Mining Africa 2024. It will also focus on current trends across industries, from increasing environmental, social and governance (ESG) requirements to sustainability, the Just Energy Transition and energy efficiency. All these developments are driving an increased uptake in digitisation and automation as companies look to become more responsible and resilient.
ABB Ability™ eMine comprises a portfolio of electrification technologies to enable greater efficiencies in mining.
In the context of transformation in secondary distribution networks in the energy sector, ABB will showcase its Compact Secondary Substations (CSS), which include medium voltage (MV) switchgear, distribution transformers, and low voltage (LV) switchboards. Key features include higher levels of safety for personnel and equipment due to the highest degree of internal arc classification.
The CSS units are available in various configurations and materials, including steel and innovative GRP housing, depending on the needs of the project application. They are suitable for a range of industries, from renewables to utilities and infrastructure. “The CSS units reflect ABB’s commitment to creating safer, more efficient and sustainable solutions for modern electrical distribution needs,” says Graham Abrahams, Senior Vice President, Electrification Commercial Leader.
Another innovation from ABB Electrification is the UniGear ZS1 switchgear, which supports applications from utility substations to industrial plants. It is available in various configurations, including single busbar, double busbar, and double level solutions. The switchgear features a slim panel width of only 500 mm, making it one of the most compact air-insulated switchgears available. It is designed to save space without compromising performance.
Advanced safety features include a system that actively prevents electric shock accidents and enhances equipment safety. The UniGear ZS1 can handle up to 24 kV, 4 000 A, and 63 kA, making it suitable for demanding environments. It also incorporates tubular busbar technology for optimised electricity distribution and improved heat dissipation.
The switchgear is IoT-enabled, integrating digital technologies to provide real-time monitoring and analysis. This allows for improved asset management, predictive maintenance, and improved operational reliability. With over 500 000 panels installed worldwide, the UniGear ZS1 is a proven solution supported by ABB’s global network.
“It is all about leveraging electrical infrastructure and technologies to improve efficiencies,” says Martin van Zyl, Sales Manager, Process Automation, ABB South Africa. This includes high-efficiency motors, advanced magnetic motor controls, hoisting technologies, and energy management systems, all part of a broad portfolio available from ABB.
ABB Ability™ eMine comprises electrification technologies that enable the all-electric mine, integrating digital applications and services to monitor and optimise energy usage. It extends from the electrification of mining trucks to the entire mining process. In addition to haulage, the portfolio includes the electrification of ABB’s more traditional solutions for mining like hoisting, grinding, and materials handling.
An example of this is the pilot technology eMine™ FastCharge, set to be the world’s fastest and only fully automated charging system for mining trucks, offering up to 600 kW of power. Used in tolley-assisted hauling, the eMine™ Trolley System can reduce diesel consumption and resulting carbon emissions by up to 90% compared to all-diesel operations.
ABB is also demonstrating energy efficiency, showcasing the energy savings achievable with drives compared to conventional damper-controlled fan systems or valve-controlled pump systems. The demo application highlights the power consumption of both options in real-time bar graphs for easy comparison, and shows the calculated annual savings.
ABB also offers energy efficiency appraisals to assist mining engineers in determing the payback period of installing a variable speed drive (VSD) or upgrading to a higher efficiency motor. ABB VSDs can assist with sustainability, enabling real-time energy savings and CO2 emissions reduction.
VSDs can be used together with energy-efficient, low voltage motors based on Synchronous Reluctance Motor (SynRM) technology to achieve IE5 efficiency. An IE5 SynRM motor achieves a 50% reduction in energy losses compared to an older IE2 motor and a 40% reduction compared to traditional IE3 motors. Upgrading from older induction motors is straightforward as IE5 SynRM motors are available in the same standard dimensions and output power classes so, in many cases, they can be drop-in replacements.
Next-generation SynRM motor technology combines ultra-premium energy efficiency with effective liquid cooling to deliver high-power density, quiet operation, and excellent reliability. Sean McCree, Product Marketing Manager, ABB Motion South Africa says ABB is developing the world’s first IE5 SynRM liquid-cooled motors, ranging from 75 kW to 710 kW. The new design sets another benchmark for high power output and reliability in a compact footprint. A key advantage is that there is no need for fans or ventilation systems for cooling, so the ambient air is undisturbed. This feature is particularly beneficial in mining and other industrial environments where dust contamination can be problematic.
Regarding safety in mining in particular, ABB has been engineering hoist systems for over 130 years to support efficient and safe mining. Its latest products include the BHX hoist control system to enhance the safety, reliability, and efficiency of hoist operations, says Mike Davis, Global Product Manager ABB. It integrates easily with other ABB technologies such as the ABB Ability™ NGX Hoist Control, which offers flexibility and can replace older or third-party systems.
ABB aligns its efforts with the UN Sustainable Development Goals: SDG 7 (for affordable and clean energy), SDG 8 (decent work and economic growth), SDG 9 (industry, innovation, and infrastructure), and SDG 13 (climate action). As well as making gradual improvements in its products and solutions the company aims for transformative changes that drive real progress towards a sustainable future. It is working with various stakeholders to embed sustainable practices across diverse industries to contribute to this.
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