AUTHOR

Turing

Related Topics

Mining

Workforce Management

AI/Machine Learning

Turing, a digital solutions provider, was able to deliver it’s exclusive, integrated O&M management solution for water production in gypsum washing for Gradiant’s mining customer, Rio Tinto. The SmartOps AI digital platform utilising TOP Clear technology facilitated state-of-the-art operations management, maximising water production efficiency.

THE CHALLENGE

The DSL Lake MacLeod site, situated 900 kilometers from Perth, the capital city of Western Australia, faced significant challenges in gypsum production due to the unreliable freshwater output from a rental reverse osmosis (RO) plant.

The plant necessitated substantial outsourced labour to maintain operational status and address frequent maintenance needs, resulting in high operating expenses. The remote location of the site further exacerbated the issue, making it difficult and costly to secure skilled labour on-site.

THE SOLUTION

Gradiant implemented a comprehensive build, own, operate, and transfer (BOOT) solution to address the challenges at the DSL Lake MacLeod site. This approach focused on minimising operating expenses through innovative process engineering and the integration of Turing’s exclusive SmartOps AI digital operating and maintenance software.

The plant was equipped with an extensive array of sensors and automation, all managed by our SmartOps AI software platform. This advanced SCADA system which utilises our TOP Clear technology, leverages artificial intelligence (AI) and Industrial Internet of Things (IIoT) for predictive operations, maintenance, and operating expense optimisation.

SmartOps AI enabled immediate remote operations management through real-time anomaly detection, monitoring, and control by our experts. AI algorithms were deployed to forecast maintenance requirements, such as the timing for filter replacements and membrane cleanings. Additionally, AI algorithms optimised processes for maximum efficiency in water production, energy use, and chemical consumption.

Preventive maintenance was performed by Gradiant technicians on a monthly to bi-monthly basis, ensuring consistent and reliable plant operations.

RESULTS

For Rio Tinto, the impact has been profound. SmartOps AI simplified the complexities of O&M at their process water supply facility, especially given its remote location. The platform alleviated the need for managing skilled labour on-site and mitigated technical and performance risks associated with advanced water treatment technologies.

The new plant, controlled by SmartOps AI, consistently produced the required process water for gypsum at lower costs than the guaranteed OPEX, a stark contrast to the old rental plant. Feedback from the site highlighted another benefit: the quality of gypsum improved due to the reliable, high-quality process water.

SmartOps AI didn’t just streamline operations; it elevated the entire process, setting a new standard for efficiency and quality.