AAEngineering Group Uses Digital Twins to Save 30% in Design Time to Deliver Gold Production Facility in Kazakhstan

The Year in Infrastructure Awards (now known as the Going Digital Awards) is an exciting and well-regarded global competition that recognizes digital advancements in infrastructure. Since 2004, this awards program has recognized over 4,000 of the world’s most outstanding infrastructure projects. It is a unique program that is truly global in scope and comprehensive in the categories and industries covered, encompassing all forms of infrastructure projects from around the world.

In 2020, AAEngineering won the award in the Going Digital: Advancements in Mining and Offshore Engineering category. Their remarkable project fully utilized digital twin technologies from Bentley Systems, which spanned the entire lifecycle from initial concepts right through to digital handover. The project involved constructing new facilities alongside and tying into an existing operation, a very common requirement as companies build on and expand their existing assets. Digital twins are ideal for such projects, where there is the need to capture the as-is conditions. They enable companies to explore all options so that they can make the best decisions for both the new facilities and the existing plants, then ensuring the digital handover of accurate, up-to-date information for little to no disruption of production. Read on for more details about this remarkable project.

Expanding Gold Ore Processing Production
When drilling and geological studies in Kazakhstan confirmed the presence of gold ores in the surrounding Akmola region, gold producer Altynalmas invested in expanding resource extraction and annual ore processing production up to 5 million tons. The USD 230 million-dollar project included construction of a new processing plant, a dam, accommodation camp, water pipelines, and a 220-kilovolt electrical substation that required an upgrade of the existing energy infrastructure. AAEngineering Group was tasked with overall design, procurement, and construction works, requiring digital deliverables that aligned with the client’s digital mine program. They faced strict environmental regulations and integration requirements with existing gold plants, compounded by a limited footprint, a short timeline, and coordination challenges during COVID-19.

Visualizing Infrastructure Options, Streamlining Execution
AAEngineering wanted to present several conceptual models to enable the client to visualize the infrastructure design options and make the most informed decision for implementing the project. They sought to demonstrate their commitment to the client’s digitalization efforts, providing seamless integration with three existing factories and their operations systems using digital twins. To reduce construction time and meet the tight schedule, they also proposed simultaneously executing design and construction works. However, to achieve these deliverables, meet the client’s smart mining initiatives, and manage the remote project team during the pandemic, AAEngineering needed integrated BIM and digital twin technology and an open, connected data environment.

Open Applications Provide Integrated Solution
At the conceptual modeling stage, AAEngineering established a collaborative design environment using ProjectWise. With ContextCapture, they processed laser scans and unmanned aerial vehicle (UAV) captured images of the existing facilities and new construction site. They assessed earthworks and generated a digital terrain model in OpenRoads. Using OpenPlant, they digitalized existing and new pipeline layouts and equipment connections to develop several conceptual 3D models for the client. The detailed design and architectural modeling were performed using OpenBuildings Designer, and the information model was synchronized with SYNCHRO 4D for construction simulation and scheduling. LumenRT facilitated visual clash detection while iTwin Services provided the cloud-based platform to establish a digital twin and seamless integration with the client’s operating system to support intelligent mining processes and management.

Digitalization Revolutionizes Industry
Using Bentley’s open 3D and 4D modeling applications and digital twin technology, AAEngineering performed concurrent design and construction works that resulted in plant commissioning ahead of schedule, reducing construction costs. Working in a collaborative digital environment and updating the development model with unmanned aerial vehicle surveys saved 30% in design time and cut travel expenses by 75%, optimizing remote coordination and construction management during the COVID-19 quarantine. Through accurate modeling and visualization, they reduced material quantities by 15% and eliminated clashes during construction. The digital twin enables the client to train operations staff prior to commissioning and promotes automation and digitalization of processes that are revolutionizing the mining industry.

“To sum it all up, Bentley Systems enabled us to improve our own design, construction, and operations solutions.”

— Andrey Aksyonov, Director of Information Modeling Department, AAEngineering Group

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Author: Anne-Marie Walters, Industry Marketing Director, Process and Resource Industries, Bentley Systems