Baoshan Mining Co., Ltd. Revolutionizes Ore Processing with "Dark Factory"

The concept of "dark factories" is common, but what does an ore processing "dark factory" look like? Baoshan Mining Co., Ltd. has provided an answer. On the production side, from raw ore to iron concentrate, the processes of transportation, processing, and inspection require no on-site manual operation. On the equipment side, predictive maintenance is achieved, the production line remains stable and controlled, and maintenance personnel are not stationed at the factory. On the operational side, lean operations are realized, establishing an efficient, low-carbon, and intelligent operating model. Thanks to the "dark factory," the company has achieved leading productivity metrics in the ore processing industry in recent years.

How is the unmanned production site realized? Entering the grinding and magnetic separation workshop, the huge roar echoes within this factory building, which is about 100 meters long, 50 meters wide, and 30 meters high. Climbing to the second-floor operating platform, the wheels on two large ball mills with a diameter of 6.2 meters are spinning rapidly. Not far away, a grinding and magnetic inspection robot, with its lights flashing, is collecting data on equipment temperature, vibration, and other conditions.

Is a "dark factory" completely dark? With robots performing 10 inspections, identifying 264 potential equipment defects, Stone Crusher and achieving a production line failure rate of zero... Inside the factory, a large screen displays real-time operational parameters of various equipment. "The 'dark factory' is not pitch black; it emphasizes a highly intelligent production method. From raw materials to the final product, intelligent robots and automated equipment complete the process according to the instructions of the software system," said the company's Deputy Equipment Manager.

"The magnetic separator uses magnetic force to attract 12mm iron particles, which are then ground into 75-micron powder by the ball mill. After adding water, slurry is formed," said Liu Chunhui. Previously, this factory had 4 shifts, each with 15 to 20 people. After digital transformation, the entire factory now only requires 4 to 5 employees to handle emergency situations.