Ball Charge Monitoring System for the Ball Mills at the Sarcheshmeh Copper Complex Concentrator Plant

Monitoring and controlling overhead crane operations and providing a variety of reports

In previous years, the weighing and dispatch unit at the Jalalabad Mine of Foolad Zarrand Iranian Company used various software systems. Due to their outdated workflows, these systems had several shortcomings and could not meet the unit’s evolving needs. Problems with the legacy systems included traffic congestion caused by staff having to enter vehicle details manually, as well as wasted staff time and effort. In addition, because the workflows were offline, no real-time statistics or live data were available. These systems also lacked safety and deterrence mechanisms, and did not support checks on trucks’ rated capacity, expiry dates, or transportation duration.

In recent years, ZISCO had a pressing need to provide the finance and warehousing departments, as well as management, with access to this information so they could make timely, data-driven decisions and take appropriate action when potential issues arose. Therefore, after preparing the necessary infrastructure, ZISCO began working with Control Adad to automate the weighing and dispatch unit.

After visiting the dispatch and distribution unit at Jalalabad Mine and the plant’s ICT department, Control Adad specialists held several meetings with the mine management and the plant’s ICT team. They identified the requirements and, taking the available facilities and infrastructure into account, designed and implemented their intelligent weighing system around four main pillars:

• ●Real-time integration of data from weighing stations
• ●Maximizing the operational availability of weighing stations
• ●A simple, user-friendly system
• ●High system extensibility for adding new capabilities

Once the system was deployed at the mine’s weighing unit, the estimated weighing time was significantly reduced, helping control traffic at both the origin and destination. Synchronizing the weighing stations also prevented the weighbridge pages from remaining static or becoming limited to a single user. The statistics below clearly demonstrate these results.

Certificates of Appreciation

Products Used in This Project

Some of Control Adad’s Most Powerful Automation and Software Products