Global technology company ABB has helped Atalaya Mining to optimize mill availability and performance by combining its gearless mill drive (GMD) with ongoing lifecycle management support and a digital condition monitoring solution through a long-term service agreement (LTSA).

The mining company, which produces copper concentrates and silver by-product at its Project Riotinto site in the Andalucía region of southwest Spain, uses an ABB GMD, the most powerful mill drive system on the market. It is considered as the ‘workhorse’ for grinding operations, providing reliability and availability for processing plants such as Riotinto, which has a processing capacity of up to 15 Mtpa.

After its recent expansion, Riotinto mine increased its annual copper production target to approximately 55,000 tonnes per year. The ABB long-term service agreement (LTSA) with an ABB Lifecycle Manager has supported a production record at the mine in 2020 and production was approximately the same in 2021.

Through the service program, Atalaya Mining benefits from lifecycle management to plan, coordinate and execute services, including corrective, preventive and predictive system maintenance with rapid response to emergency calls and an adaptive approach to meet modifications in production, maintenance or shutdown schedules. This means minimizing the risk of costly unscheduled downtime, extending the life of installed systems and optimizing process performance.

At the same time, ABB Ability Predictive Maintenance for grinding, a digital condition monitoring solution to maintain, assess and analyze GMD systems and increase safety through continuous checks, has been deployed. It considers past and real-time data to anticipate maintenance requirements and to avoid unplanned production downtime.

Overall, the LTSA maximizes availability, optimizes asset performance and facilitates safe operation of the equipment through a single-point-of-contact, ABB’s Remote Diagnostic Services, routine maintenance and upgrades.

“The combination of ABB GMD design, the continuous monitoring and the use of ABB Ability™ Predictive Maintenance for grinding means that the system is working at its highest efficiency,” said Dimitris Fotiadis, Head of Lifecycle Care, ABB. “ABB will continue to support Atalaya Mining through machine operation and routine maintenance over the long term.”

ABB has provided more than 150 gearless mill drives to customers around the world over the last 50 years. ABB gearless mill drives draw on the ABB distributed control system, ABB Ability™ System 800xA and offer advanced mill control functions including frozen charge detection, frozen charge remover, controlled rollback, automatic positioning and advanced monitoring.

ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 105,000 talented employees in over 100 countries.

ABB’s Process Automation business is a leader in automation, electrification and digitalization for the process and hybrid industries. We serve our customers with a broad portfolio of products, systems, and end-to-end solutions, including our #1 distributed control system, software, and lifecycle services, industry-specific products as well as measurement and analytics, marine and turbocharging offerings. As the global #2 in the market, we build on our deep domain expertise, diverse team and global footprint, and are dedicated to helping our customers increase competitiveness, improve their return on investment and run safe, smart, and sustainable operations.