- This BHP project involves the use of advanced techniques to drill deep shafts without explosives, allowing continuous circulation of fresh air while removing polluted air to ensure efficient underground ventilation, critical for miner safety.
- BHP partnered with ABB to deploy state-of-the-art ACS880-37 ultra-low harmonic drives and AMI 560L8A high-voltage motors.
- These solutions have significantly improved energy efficiency, saving over $120,000 annually per fan while reducing harmonic distortions and ensuring operational reliability.
BHP is a world-leading resources company. With more than 90,000 employees and contractors, they work in more than 90 locations worldwide and their products are sold globally. BHP is focused on the resources the world needs to grow and decarbonise. Population growth, decarbonisation, urbanisation and improving living standards are global trends that underpin strong demand for the commodities they produce.
BHP’s largest operation in South Australia is Olympic Dam, one of the world’s most significant deposits of copper, gold and uranium. BHP has been continuously innovating at Olympic Dam to enhance the mine's operations, particularly through their ongoing raise bore project.
The raise bore project at Olympic Dam is critical for ensuring reliable underground mine ventilation. This project circulates fresh air, safeguarding the health and safety of the miners working hundreds of metres below ground. The technique involves drilling shafts up to 800 metres deep without using explosives, creating ventilation systems that draw polluted air out and allow fresh air to circulate on a constant cycle.
Without the appropriate equipment, issues such as harmonics and high starting currents can arise, potentially causing network interference and limiting power capacity.
A key challenge identified during the project was the energy demand of existing equipment, particularly the competing requirements from other areas of the mine which can put pressure on the site’s overall power network. Without the appropriate equipment, issues such as harmonics and high starting currents can arise, potentially causing network interference and limiting power capacity. Addressing these constraints is critical to ensuring reliable and efficient energy usage across the site.
To address these challenges, BHP turned to ABB's advanced technology. Tim Bott, the Construction Supervisor for electrical and refrigeration with copper coal asset projects at Olympic Dam, highlighted the benefits of ABB's ACS880-37 cabinet-built ultra-low harmonic (ULH) drives.
"The drives, combined with ABB's AMI 560L8A high voltage modular induction motors, have enabled BHP to save over $120K per fan annually."
“Total harmonic current distortion of these drives is typically less than 3%, significantly improving input energy efficiency and maintaining near unity power factor. The drives, combined with ABB's AMI 560L8A high voltage modular induction motors, have enabled BHP to move the same air volume at reduced RPM, saving over $120K per fan annually. That’s a substantial increase in energy efficiency for our operations.”
ABB’s compact ACS880-37 ULH drive generates exceptionally low harmonic content in its input without needing external filters or multi-pulse transformers. Compatible with most industrial processes and automation systems, the drive's active supply unit can boost output voltage, ensuring full motor voltage even when the supply voltage is below nominal. These drives are exceptionally robust, thanks to their inherently long lifetime design.
ABB’s high voltage modular induction AMI 560L8A motors deliver exceptional efficiency and reliability, even in the most demanding applications. Designed to enhance reliability, energy efficiency, and productivity across various industries, these motors feature modular mechanical construction and advanced electrical designs.
The AMI Series offers several advantages, including very low vibration levels, low noise, and 2-pole stiff shaft motors that are ideal for variable-speed drive applications. These motors are designed for various types of environments, including hazardous areas and offshore installations. For the Olympic Dam project, the AMI motors were further customised to meet BHP’s specific design requirements.
Some of the 5 tonne fan impellers on site at BHP Olympic Dam, waiting to be installed. 
View from the top of a raise bore application, under construction. 
One of the eight ABB ACS880-37 ULH cabinet drives installed inside an Olympic Dam switchroom. 
One of the eight ABB AMI 560 motors already installed and operational at Olympic Dam. 
BHP Olympic Dam’s newest raise bore fan now in operation.
So far, BHP has installed eight of ABB’s 690V, 800KW AMI 560L8A motors and matching ACS880-37 ULH drives, with preparations already underway for additional installations.
Arvind Sharma, ABB Motion Australia Business Development Manager for Drive Products, emphasised the importance of air ventilation for mine operations and expressed his delight in collaborating with BHP as well as their project consultant to identify the best motor and drive technology for their ventilation systems.
"This partnership not only ensures safe operations but also plays a crucial role in reducing network disturbances and significantly increasing energy efficiency, supporting BHP’s Healthy Environment goals. Enhancing energy efficiency is vital for mine sites, as it not only generates cost savings, but also supports sustainable mining practices," said Arvind.
Tim concluded that the seamless integration and robust technical support provided by ABB, combined with the advantages of utilising motors and drives from a single trusted supplier, will remain a significant asset for their operations in years to come.
ABB is a global technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. By connecting its engineering and digitalization expertise, ABB helps industries run at high performance, while becoming more efficient, productive and sustainable so they outperform. At ABB we call this ‘Engineered to Outrun’. Building on over 140 years of excellence and with more than 105,000 employees worldwide, ABB optimizes how things are manufactured, moved, powered and protected. The company’s shares are listed on the SIX Swiss Exchange (ABBN) and Nasdaq Stockholm (ABB). At the heart of the energy transition, ABB helps the world’s industries outrun – leaner and cleaner. www.abb.com
ABB Motion, a global leader in motors and drives, is at the core of accelerating a more productive and sustainable future. We innovate and push the boundaries of technology to contribute to energy efficient, decarbonizing and circular solutions for customers, industries and societies. With our digitally enabled drives, motors and services we support our customers and partners to achieve better performance, safety and reliability. To help the world’s industries outrun – leaner and cleaner, we deliver motor-driven solutions for a wide range of applications in all industrial segments. Building on over 140 years of domain expertise in electric powertrains, our more than 22,000 employees across 100 countries learn and improve every day. go.abb/motion
