Process Automation System Streamlines Production

New system from Rockwell Automation helps 14 disparate mining buildings operate on a single, unified control system

Background

The recent boom in the number of mobile devices – such as laptops, tablets and smartphones – has led to a renewed look at the suppliers of the essential components that make them function. For example, LCD screen images and speaker technology are enabled by rare earth elements mined from below the earth’s surface.

Many of these elements are imported from China. A recent push from the United States government has opened the door for increased domestic supply of rare earth minerals.

In response to this opportunity, a leading global manufacturer of rare earth and metal products acquired a facility in California with the goal of converting it to a state-of-the-art mining and processing operation. The massive $1 billion project spanned 14 buildings at this location and required standardizing on a common control system across each facility.

At the facility, ore is mined from one of the world’s largest and richest rare earth mineral deposits. Once mined, the ore is crushed, milled and concentrated on-site. It is then put through chemical processing to remove any impurities. Heavy and light rare earth minerals are then concentrated, processed and separated either at Mountain Pass or another downstream facility.

Other on-site facilities include heat and power plants, and a chloralkali facility that takes wastewater produced and turns it back into chemical re-agents used in the separation process. In addition, a paste tailings plant removes water from non-rare earth tailings. The water is then recycled, and the tailings are converted into low-moisture material to prevent the elements from being released to the environment.

The upgraded facility mines and processes rare earth minerals that are used in smartphones, electric cars, wind turbines, and defense guidance system magnets, as well as countless other products.