Bentley Case Studies AAEngineering's Digital Transformation of Kazakhstan Gold Ore Processing Plant Amid COVID-19

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	AAEngineering's Digital Transformation of Kazakhstan Gold Ore Processing Plant Amid COVID-19 Bentley

AAEngineering's Digital Transformation of Kazakhstan Gold Ore Processing Plant Amid COVID-19

Bentley

Technology Category	Analytics & Modeling - Digital Twin / Simulation Sensors - GPS
Applicable Industries	Construction & Infrastructure Mining
Applicable Functions	Procurement Product Research & Development
Use Cases	Construction Management Digital Twin
Services	System Integration
Challenge	AAEngineering Group was tasked with the design, procurement, and construction of a new gold processing plant in Aksu, Akmola Region, Kazakhstan. The project was part of an initiative by gold producer Altynalmas to expand their annual ore processing production up to 5 million tons. The USD 230 million project included the construction of a new gold processing plant, a dam, accommodation camp for 600 people, water pipelines, and a 220-kilovolt electrical substation. The challenge was to upgrade the existing energy and mining infrastructure, ensure environmental protection and occupational safety, and determine an optimal construction site that mandated a 1,000-meter sanitary protection zone from adjacent pits and uranium dams. The new plant also needed to be interoperable with the existing processing facilities in terms of equipment and materials, and seamlessly integrate with the operating systems. Additionally, AAEngineering faced challenges meeting the technology demands to comply with the client’s Digital Mine initiative on a tight timeline, compounded by coordinating a remote team during the COVID-19 pandemic. Read More
About Customer	The customer, Altynalmas, is a gold producer based in Kazakhstan. As a driver in the Asian mining industry with vast amounts of available natural minerals, Kazakhstan is developing its mining infrastructure to explore and capitalize on these reserves. When drilling and geological studies revealed the presence of gold ores in the surrounding Akmola region, Altynalmas invested in expanding resource extraction operations. With already three existing nearby factories, the organization announced a tender to increase their annual ore processing production up to 5 million tons. The USD 230 million project included construction of a new gold processing plant, a dam, accommodation camp for 600 people, water pipelines, and a 220-kilovolt electrical substation. Read More
Solution	AAEngineering leveraged Bentley’s open applications to establish a collaborative design platform using ProjectWise. They used laser scanning and unmanned aerial vehicles (UAVs) to survey the existing facilities and the new construction site, processing the captured images with ContextCapture. From the survey data, they assessed earthworks and generated a digital terrain model in OpenRoads. Then, using OpenPlant, they digitized existing and new pipeline layouts and equipment connections to develop several conceptual 3D models for the client. Based on the client’s specifications, AAEngineering used various software applications to assemble the pipeline and structural models, along with the accommodation camp. They then integrated these models with the general plant model in OpenBuildings Designer. AAEngineering used ContextCapture to process weekly UAV-captured images into reality meshes and synchronized the models with SYNCHRO 4D for construction simulation and scheduling. Incorporating LumenRT and iTwin Services facilitated visual clash detection and provided the cloud-based platform to establish a digital twin. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Sensors - GPS

Applicable Industries

Construction & Infrastructure

Mining

Applicable Functions

Procurement

Product Research & Development

Use Cases

Construction Management

Digital Twin

Services

System Integration

Challenge

AAEngineering Group was tasked with the design, procurement, and construction of a new gold processing plant in Aksu, Akmola Region, Kazakhstan. The project was part of an initiative by gold producer Altynalmas to expand their annual ore processing production up to 5 million tons. The USD 230 million project included the construction of a new gold processing plant, a dam, accommodation camp for 600 people, water pipelines, and a 220-kilovolt electrical substation. The challenge was to upgrade the existing energy and mining infrastructure, ensure environmental protection and occupational safety, and determine an optimal construction site that mandated a 1,000-meter sanitary protection zone from adjacent pits and uranium dams. The new plant also needed to be interoperable with the existing processing facilities in terms of equipment and materials, and seamlessly integrate with the operating systems. Additionally, AAEngineering faced challenges meeting the technology demands to comply with the client’s Digital Mine initiative on a tight timeline, compounded by coordinating a remote team during the COVID-19 pandemic.

About Customer

The customer, Altynalmas, is a gold producer based in Kazakhstan. As a driver in the Asian mining industry with vast amounts of available natural minerals, Kazakhstan is developing its mining infrastructure to explore and capitalize on these reserves. When drilling and geological studies revealed the presence of gold ores in the surrounding Akmola region, Altynalmas invested in expanding resource extraction operations. With already three existing nearby factories, the organization announced a tender to increase their annual ore processing production up to 5 million tons. The USD 230 million project included construction of a new gold processing plant, a dam, accommodation camp for 600 people, water pipelines, and a 220-kilovolt electrical substation.

Solution

AAEngineering leveraged Bentley’s open applications to establish a collaborative design platform using ProjectWise. They used laser scanning and unmanned aerial vehicles (UAVs) to survey the existing facilities and the new construction site, processing the captured images with ContextCapture. From the survey data, they assessed earthworks and generated a digital terrain model in OpenRoads. Then, using OpenPlant, they digitized existing and new pipeline layouts and equipment connections to develop several conceptual 3D models for the client. Based on the client’s specifications, AAEngineering used various software applications to assemble the pipeline and structural models, along with the accommodation camp. They then integrated these models with the general plant model in OpenBuildings Designer. AAEngineering used ContextCapture to process weekly UAV-captured images into reality meshes and synchronized the models with SYNCHRO 4D for construction simulation and scheduling. Incorporating LumenRT and iTwin Services facilitated visual clash detection and provided the cloud-based platform to establish a digital twin.

Impact #1	The use of Bentley technology during the conceptual phase resulted in a well-developed visual bid for the project, providing the client with a full understanding of the design right from the start and winning AAEngineering the contract. The integrated modeling applications and digital twin solution streamlined workflows and facilitated concurrent design and construction. Working in a collaborative digital environment and updating the development model with UAV surveys optimized remote coordination and construction management during the COVID-19 quarantine. The digital twin enabled seamless integration with the client’s operating system in accordance with their digital mine initiative to support intelligent mining processes and management, promoting automation and digitalization that are transforming the mining industry. For AAEngineering, implementing the use of digital twin technology on this project provided economic efficiencies and has instilled new corporate processes, making advanced digital practices a company standard. Their advanced technological approach offers a competitive advantage that has made them a regional leader with a signed portfolio of engineering, procurement, and construction contracts for the next five years.

Impact #1

The use of Bentley technology during the conceptual phase resulted in a well-developed visual bid for the project, providing the client with a full understanding of the design right from the start and winning AAEngineering the contract. The integrated modeling applications and digital twin solution streamlined workflows and facilitated concurrent design and construction. Working in a collaborative digital environment and updating the development model with UAV surveys optimized remote coordination and construction management during the COVID-19 quarantine. The digital twin enabled seamless integration with the client’s operating system in accordance with their digital mine initiative to support intelligent mining processes and management, promoting automation and digitalization that are transforming the mining industry. For AAEngineering, implementing the use of digital twin technology on this project provided economic efficiencies and has instilled new corporate processes, making advanced digital practices a company standard. Their advanced technological approach offers a competitive advantage that has made them a regional leader with a signed portfolio of engineering, procurement, and construction contracts for the next five years.

Benefit #1	Reduced design time by 30%
Benefit #2	Reduced construction period, enabling plant commissioning ahead of schedule
Benefit #3	Cut travel expenses by 75%

Benefit #1

Reduced design time by 30%

Benefit #2

Reduced construction period, enabling plant commissioning ahead of schedule

Benefit #3

Cut travel expenses by 75%

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Overview

AAEngineering's Digital Transformation of Kazakhstan Gold Ore Processing Plant Amid COVID-19

Operational Impact

Quantitative Benefit