Train Loading Automation for Anglo American

Intro

Anglo American is the world's third-largest exporter of metallurgical coal. The company uses the latest technology to run their operations in the best possible way and strive for continuous improvement at existing assets. They produce and export quality steelmaking coal, which is used in steel production for critical building and infastructure around the world.

The challenges

Coal is often transported from the mines to ports using hopper wagons on railway infrastructure. Railway infrastructure has many restrictions and requirements around loading weights, overloading, and inconsistent loading, issuing fines when restrictions are not allowed. These restrictions are in place because not following them increases the likelihood of damage to the railway, train derailments, and injury.

Many sites have operators who manually fill each wagon to the optimal level. This increases the risk of fatigue and visibility challenges (especially from dust).

The solution

MRA deployed its industry-leading Train Load Out automation solution to complement the existing ControlLogix PLC and SCADA. MRA’s offering is a mature solution that has operated on over 11 million wagons.

The results

1. Efficient and Reliable Loading - The TLO system accounts for variables such as environmental conditions, time of day and operator fatigue.
2. Ease of Commissioning - Remote commissioning by accessing the controller online provides increased efficiency and flexibility. 
3. Unrivalled ROI - Return on investment of less than four months for the system.
4. Detailed Simulation - by collecting data and analysing trend simulation can be performed prior to commissioning to reduce downtime.

“The coding that MRA developed within the ControlLogix PLC is extremely efficient and reliable. We are now using it for 98 per cent of loading, with only 2 per cent being loaded manually as a result of external factors. This TLO system is an integral part of our pit-to-port operation - the end goal is to make sure our trains are fully loaded.”

Anthony Manousso, Anglo American