Why Ok Tedi chose Aspen Mtell® to future-proof its operations
Provision of Asset Management System
- Papua New Guinea
- Aspen Mtell®
- Mining
A smarter way forward
At the Ok Tedi copper and gold mine in Papua New Guinea’s remote Western Province, equipment reliability is critical. With limited access to parts and support, unplanned downtime carries significant production and cost consequences.
Following a series of breakdowns, Ok Tedi Mining Limited (OTML) sought a solution that could improve asset performance and reduce the risk of unexpected failures. They engaged Mipac as a trusted advisor and long-standing operation partner to identify the most suitable asset management system for their needs.
A trusted partner
Mipac had already delivered and continues to deliver several key projects at Ok Tedi, including the Automation Roadmap, Power Improvement and Processing Asset Renewal projects. This established relationship gave Mipac a detailed understanding of the site’s infrastructure, challenges and priorities.
OTML’s objective was clear: to identify a forward-looking system that could detect early signs of equipment degradation, predict potential failures and support more targeted maintenance planning. There was particular interest in solutions that leveraged artificial intelligence and machine learning to deliver these outcomes.
A considered approach
Mipac undertook a comprehensive evaluation of available asset management systems, with a focus on platforms capable of predictive diagnostics and real-time insight.
Aspen Mtell® emerged as the most appropriate solution. It offers advanced machine learning capabilities to identify patterns in live and historical sensor data, providing early warnings of failure and insights into equipment behaviour over time. The evaluation concluded in November 2023, with a recommendation to proceed with Mtell®.
The initial implementation
In collaboration with AspenTech, Mipac was engaged to deploy Mtell® across ten high-priority assets in the crushing and grinding circuit as a thin slice test of the system.
Under the agreed approach:
- The first five assets were to be delivered by AspenTech, with support from Mipac
- The remaining five were to be delivered by Mipac
- The Mtell® system would be trained and deployed using time-series data and maintenance history from existing OTML systems
The project commenced in May 2024, with a timeline that included:
- A four-month implementation period
- Nine months of post-deployment support and mentoring
The AspenTech Mtell® system
Aspen Mtell® software is a powerful equipment analytics solution that accurately predicts an anomaly in monitored equipment and its related process, indicating precisely when and how an event is likely to occur. This solution leverages machine learning to identify and alert on early patterns of degradation which lead to reduction in useful life. The resulting output provides insights that can assist in the containment of risk, supporting a strategic transformation program, which can drive net results with an increase in production output and a reduction in expenses relating to equipment ownership, maintenance costs and overall energy consumption.
The Mtell® software executes very precise pattern recognition of changes in streaming signals produced from sensors on and around the equipment being monitored. This permits detection of extremely early onset of equipment degradation through multi-variate differences across all the streaming signals and through temporal distinctions: tiny changes in the streaming signals, offset by time.
Visit the AspenTech website for more information.
Enabling more proactive maintenance
Aspen Mtell® provides more than traditional condition monitoring. Its intelligent software agents continuously analyse data streams to detect subtle, multivariate changes that signal potential issues. This enables much earlier identification of problems that cause unplanned equipment failures — often well before they can be observed through existing systems at OTML.
By adopting this predictive approach, OTML aims to reduce maintenance-related downtime, improve asset availability and relieve pressure on site-based maintenance teams.
A strategic step forward
For OTML, the adoption of Mtell® represents a shift towards more data-informed, proactive asset management. For Mipac, it reflects an ongoing commitment to bringing the most effective technologies to clients — backed by careful evaluation and alignment with operational goals.
The implementation lays the groundwork for a more reliable, responsive maintenance strategy at one of the region’s most significant mining operations.
Want to know more about how Aspen Mtell® can optimise your complex mineral processing operation?
Aspen Mtell goes beyond traditional monitoring by becoming a proactive guardian of your assets. It deploys intelligent “agents” that continuously monitor and analyse sensor data from your critical equipment. These agents leverage various methodologies to predict potential failures before they occur. Read more about AspenTech Mtell.