PT SMM — CHPP Optimisation & Technical Advisory Services
Performance Improvement, Maintenance Management & Industrial Digitalisation | Indonesia | Commenced 2021
Project Overview
Client: PT Suprabari Mapanindo Mineral (PT SMM)
Location: Indonesia
Industry: Coal Mining & Mineral Processing
Plant Capacity: 500 tph
Annual Design Production: 3.0 million tonnes ROM feed
Project Commencement: 2021
Services: Technical Advisory, Plant Optimisation, Maintenance Management & Industrial Data Systems
Contracting Entity: Eptoscore (Pty) Ltd, South Africa
Eptoscore was appointed to provide technical and advisory services to PT Suprabari Mapanindo Mineral for its existing Coal Handling and Preparation Plant (CHPP) in Indonesia.
The assignment focused on assessing plant performance, identifying operational bottlenecks and developing practical engineering and management solutions to improve production stability, equipment availability and process control.
The principal objective was to support the achievement of the plant’s design production requirements while maintaining the required product yield and coal ash quality.
The work combined process engineering, equipment and maintenance assessments, operational improvement initiatives and the implementation of industrial data management and visualisation systems.
Scope of Services
The technical advisory and optimisation programme incorporated several interconnected areas of engineering and operational improvement:
- Plant Performance Assessment: Review of CHPP operations, production performance, process stability and equipment availability.
- Bottleneck Identification & Optimisation: Identification of technical and operational constraints affecting plant throughput, yield and product quality.
- Maintenance Management: Development and implementation of structured maintenance management practices, equipment inspections, planned shutdowns and refurbishment strategies.
- Process Control Improvement: Stabilisation and optimisation of plant production and process control under varying feed material conditions.
- Industrial Data Platform: Development and implementation of a data platform supporting the interpretation of operational, production and maintenance information.
- Digital Monitoring & Reporting: Implementation of an OPC UA-based process dashboard and historian to provide access to real-time and historical plant data.
- Technical & Operational Advisory: Collaboration with the client’s operations and maintenance personnel to evaluate, prioritise and implement improvement initiatives.
Engineering & Project Execution
Plant Assessment & Performance Optimisation
The initial technical assessment identified equipment maintenance management and plant throughput stability as two principal areas requiring improvement.
The engineering approach combined an evaluation of existing equipment and process conditions with the identification of practical improvements to the plant’s operating and maintenance arrangements.
Maintenance Management Implementation
A dedicated maintenance management system was developed and implemented in collaboration with the PT SMM operations and maintenance teams.
The programme incorporated routine inspections based on OEM requirements, planned maintenance and shutdown strategies, equipment replacement and refurbishment planning, and the management of maintenance resources and spare parts.
Process Stabilisation & Optimisation
The plant optimisation work addressed production throughput and process control under changing feed material conditions.
The programme followed a structured approach, initially focusing on stabilising plant operation before progressing to production and process optimisation.
Industrial Data Platform & Digitalisation
An important component of the assignment was the development and application of Eptoscore’s industrial Data Platform, together with a custom-designed OPC UA-based process dashboard and historian.
The platform provided the client with access to real-time and historical production, process and maintenance data.
This supported the interpretation of operational performance, identification of emerging constraints and implementation of informed operational and maintenance decisions.
Technical Challenges & Project Highlights
Integrated Plant Performance Improvement
Improving CHPP performance required an integrated approach addressing equipment availability, maintenance practices, process stability and production control rather than treating individual issues in isolation.
Variable Feed Conditions
The plant processed coal under varying feed material conditions, requiring operational and process-control arrangements capable of accommodating changes while maintaining production and product quality objectives.
Digitalisation of Operational Information
The implementation of the industrial Data Platform and OPC UA dashboard established a structured means of collecting, storing, visualising and interpreting plant information.
Collaboration with Operating Teams
The improvement programme was implemented in cooperation with PT SMM’s operations and maintenance teams, combining engineering assessments with practical operational experience.
The assignment demonstrates capabilities in industrial plant assessments, performance optimisation, maintenance engineering, process control and data-driven operational improvement.
Project Gallery
Selected photographs and industrial data visualisations illustrating the PT SMM coal processing facility, plant equipment, process control systems and operational improvement initiatives.
