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AVEVA Predictive Analytics - Nexa

Nexa Resources aimed to reduce downtime and improve asset reliability at its largest zinc smelter in Latin America through predictive analytics. It faced challenges with 11 failed predictive proofs-of-concept and high levels of corrective and unscheduled downtime. Implementing AVEVA Predictive Analytics and the PI System led to 12 predictive models being fine-tuned, a 75% reduction in unscheduled downtime hours, improved asset reliability, and reduced needs for emergency maintenance. This helped eliminate waste and production losses.

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156 views3 pages

AVEVA Predictive Analytics - Nexa

Nexa Resources aimed to reduce downtime and improve asset reliability at its largest zinc smelter in Latin America through predictive analytics. It faced challenges with 11 failed predictive proofs-of-concept and high levels of corrective and unscheduled downtime. Implementing AVEVA Predictive Analytics and the PI System led to 12 predictive models being fine-tuned, a 75% reduction in unscheduled downtime hours, improved asset reliability, and reduced needs for emergency maintenance. This helped eliminate waste and production losses.

Uploaded by

Emilio .H.S.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Nexa Resources

Increasing reliability at the largest zinc smelter in Latin America

Goals
• Reduce downtime through predictive analytics
• Improve asset reliability
• Generates early warnings and diagnostics of equipment problems
• Reduces maintenance expenses
• Eliminates waste and production losses
Challenges
Industry: Mining, Metals and Materials
• 11 Predictive PoCs failed.
Solution: AVEVA PI System, AVEVA Predictive Analytics
• According to a study for Digitalization of Maintenance, Roasting stopped 772 hours for corrective maintenance
in 2021. 649 hours due to unscheduled downtime
• Lack of instrumentation and tags.
“I am a cash hunter and I only put money where I can save
money. We have successfully implemented Predictive
Maintenance with AVEVA Predictive Analytics combined
Results
with the PI System and achieved ROI of 300% within a few
• 12 models fine tunned with AVEVA Predictive Analytics and AVEVA PI System
months.”
• 75% reduction on unscheduled downtime hours
• Improve asset reliability Warley Jose Gomes Pereira, General Manager,
• Reduce the need for emergency maintenance purchases Cajamarquilla

Source: https://resources.osisoft.com/presentations/nexa-resources---pi-system-and-predictive-analytics-for-zinc-industry/
WATCH PRESENTATION
© 2023 AVEVA Group plc and its subsidiaries. All rights reserved.
Increased Diagnostics – Few Sensors
Increased diagnostics with Ball Mill with limited number of sensors (8 tags).
• Increased OMR and Temperature (Only 4 degrees from Actual vs Prediction). This single catch:
• Sensor´s 4 degree´s increased due to higher increase at another position of • Avoided Losses: $2.1 M
asset.

Issue

Sens
or

© 2023 AVEVA Group plc and its subsidiaries. All rights reserved.
TOP 10 Mining Company realizes major cost
savings with AVEVA Predictive Analytics “ Early warning identification and
diagnosis of equipment problems with
“
predictive analytics is a big leap in our
journey towards operational excellence.
• Challenges
• Reducing the cost of mining operations and improving efficiency across the board.
• Improve safety and day-today operations

• Solution
Savings
• AVEVA Predictive Analytics was deployed as a means to provide advanced early warning
>12.0M USD Savings
notification and diagnosis of equipment problems and failures.
< 6 months
• AVEVA Predictive Analytics enables diagnostics at corporate level, reducing manual inspection
time.
• Deployed for 327 assets across 8 plants for 3 years Serving
8 plants
• Results 327 assets

• In the first 6 months:


• SAG Mill Motor failure Cost Avoidance $12M USD Increased efficiency in record
• SAG Mill Maintenance Cost Avoidance $234K USD + 72 hours of $2,136/hr operation loss time

• Ball Mill Maintenance Cost Avoidance $146K USD + 72 hours of $2,136/hr operation loss

For Internal Use Only


71 © 2023 AVEVA Group plc and its subsidiaries. All rights reserved.

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