Glencore
Kamoto Copper Company

KCC Rtduet Downtime

Project Overview

Kamoto Copper Company (KCC), a Glencore-owned mining and refining complex in the Democratic Republic of Congo, faced significant challenges in maximizing its production efficiency and reliability. Despite a substantial investment in infrastructure, KCC struggled to achieve optimal returns due to equipment downtime and a lack of standardized data collection and analysis.

To address these issues, KCC sought the expertise of Mipac, a company renowned for its work in reliability and maintenance optimization. Drawing on its experience with similar projects, particularly at Mount Isa Mines, Mipac implemented its RtDuet software to provide KCC with enhanced visibility into equipment downtime, standardized data collection, and automated reporting capabilities.

Background

KCC is an integrated facility of 2 sites, KTC the mine and concentrator and Luilu which is the Refinery.  KCC takes ore and transforms it all the way to copper cathode, which is high purity copper, so it is a large operation with a lot of different metallurgical operations.  Glencore now owns these facilities and produces both Copper and Cobalt. 

Kamoto has a fantastic orebody and a large investment had been made in the infrastructure of the mine and plant, but they had struggled with the returns so far.

Mipac was contacted by KCC as some of their team knew of our work with RtDuet from Mount Isa Mines.

Glencore KCC RtDuet

Project Scope

Mipac installed and configured RtDuet to automatically capture the equipment downtime at KCC for both their KTC concentrator and the Refinery at Luilu. 

The first step in an RtDuet project is to have a workshop with the plant stakeholders from engineering, operations, reliability and maintenance to define how RtDuet will be implemented for their site. Mipac typically had travelled to sites to hold this workshop in person. As this project happened during the Covid-19 pandemic, this was Mipac’s first remote workshop that was held over a couple of sessions using Microsoft Teams.

KCC wanted to track the downtime of more than 30 assets, so a Site License was procured, which changes the software agreement to an annual subscription, but allows for unlimited assets to be tracked.  This has allowed KCC to continue to track new or different parts of the plant as their knowledge and capability with RtDuet has grown.

RtDuet can allow for multiple languages so we worked with the KCC team to have the reason tree and time usage codes available in both English and French.  Users can switch between the languages as they need.  Training was provided to operators and engineers by video conference.

Glencore had a standard Time Usage Model that they used globally across their plants and so Mipac was able to implement this Time Usage Model for KCC to standardise their downtime tracking.

 

Mipac also configured the RtDuet Reportsync to send the RtDuet downtime data to SQL.  KCC built their own Power BI reporting by connecting to the data in SQL.

Project Challenges

Results

Mipac was able to remotely deliver and provide training for RtDuet at KCC.  Over 30 machine centres were configured across the two plants.  It allowed them to standardise their downtime capture and KPI reporting based on Glencore’s global standards.

KCC continue to use RtDuet to track and report on their equipment downtime and Mipac continues to work with them to improve the system and train personnel.

Want to know more about how we can work with your operation?

From control systems with robust software and engineering foundations to the latest innovative advancements in digital technology, Mipac delivers high-quality, intelligent solutions that drive performance.

We can help with building new operations, optimising existing operations, modernising existing operations and main automation contracting. Find out more from Mipac.

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