Agriculture and mining companies are always looking for ways to increase throughput at their bulk material handling sites. The emergence of the Internet of Things (IoT) has created new opportunities for grain sites, port terminals, and mines. Bulk material handling operators are trying to make bulk handling machines "smarter" in order to increase throughput.
But what exactly is "smart" in the context of bulk material handling? What goes into making a "completely smart" bulk handling site? Is it even possible?
In a recent article from Harvard Business Review, for a process to become completely smart, it should have these four features:
1) Monitoring
Sensors and other external data sources can continuously collect information about the condition and operation of bulk material handling equipment at an agricultural or mining site and detect anomalies. Monitoring can be done in several ways, including:
- monitoring equipment to detect signals indicating faulty performance
- monitoring equipment to avoid unscheduled maintenance
- monitoring the operations of a yard to take corrective action as soon as execution starts deviating from the plan
By collecting and storing this data, software can be used to create a model that predicts future receivals, outturns, and inventory.
2) Control Systems
Equipment can be controlled remotely and based on information collected from sensors. For example, with a real-time 3D volumetric model of stockpiles, stacking and reclaiming is performed efficiently; truck scales and weighbridges can become automated; and machines and structures at terminals are protected from collisions. Learn more in "Getting to the Right Stuff with 3D Mining Software."
3) Optimisation
Although optimisation methods have existed for many years, the increased flow of monitoring data requires these optimisation models to be run more frequently, which is now enabled by today's technologies. Real-time monitoring data from sensors can be used to optimise ship schedules, train schedules, inventory, reclaiming, and stacking in such a way that throughput is maximized and required quality levels are maintained. Today's optimisation methods dramatically improve the output, utilization, and efficiency of bulk handling equipment.
4) Autonomy
If the first three features described above are achieved, then it is possible to make the equipment autonomous. Combining monitoring, control systems, and optimisation enables bulk material handling operations to be carried out with minimal human interference. By assigning tasks to equipment, optimisation models can be used to generate tasks automatically.
The Eka Smart Bulk Handling Process
At bulk handling sites, IoT is enabling remote monitoring which increases operational efficiency and provides anomaly detection. Organizations can better manage labor costs, improve production, gain real-time visibility on inventory, lower compliance costs, and justify infrastructure changes.
At Eka, we are building systems that deliver superior efficiency and throughput to bulk handling sites across the globe. Delivering a truly smart solution requires sophisticated software. Eka’s next-generation bulk handling software is delivering higher efficiency, lower downtime, and more safety at more than 20 bulk handling sites throughout the world.
