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CIMExcel Software Inc. Slide 1 Mineral Processing Operations Simulator (MPOS) MPOS can be used for multiple purposes including, DCS system checkout, tuning,

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Presentation on theme: "CIMExcel Software Inc. Slide 1 Mineral Processing Operations Simulator (MPOS) MPOS can be used for multiple purposes including, DCS system checkout, tuning,"— Presentation transcript:

1 CIMExcel Software Inc. Slide 1 Mineral Processing Operations Simulator (MPOS) MPOS can be used for multiple purposes including, DCS system checkout, tuning, and FAT for new site operations, and or new or upgraded control systems at existing sites. Control strategy design, testing, and tuning. HMI design and testing. Equipment What-If Analysis. Operator training for new site startup. Operator training for on-going continuous improvement. P2P: Crushing, Stockpiles, Primary Mills, Secondary Mills, Flotation, Tailings, and Plant

2 CIMExcel Software Inc. Slide 2 Mineral Processing Operations Simulator (MPOS) for operator training facilities Control Room HMI Displays and Operator Inputs Control System and Motors Process Model - Accurate Operating Values and Dynamic Responses Operator Training Scenarios - Variations in Ore Quality and Failures of Equipment

3 MPOS CIMExcel Software Inc. Slide 3 MPOS Factory Acceptance Testing - Configurations Operator Interface (simulated) Standalone Interfaced to PCS HMI and Control Hardware/Software DCS and MCC (simulated) MPOS PCS hardware / software PCS Operator Interface MCC (simulated) Control Device Outputs Motor Status DCS Analog Inputs DCS Digital Inputs Operator Training Scenarios PID Setpoints and Modes Motor Start/Stop Process Variables Motor Status OPC-based Integration PID Setpoints and Modes Motor Start/Stop Process Variables Motor Status Control Device Outputs Motor Status DCS Analog Inputs DCS Digital Inputs Motor Stop/Start Motor Status PID Setpoints and Modes Motor Start/Stop

4 CIMExcel Software Inc. Slide 4 Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization

5 CIMExcel Software Inc. Slide 5 OMPC Input - Output Variables OMPC

6 MPOS CIMExcel Software Inc. Slide 6 MPOS - FAT and OTS installations for a large P2P site

7 MPOS CIMExcel Software Inc. Slide 7 MPOS - FAT and OTS for Metal Processing Copper and Molybdenum Processing Operations

8 MPOS CIMExcel Software Inc. Slide 8 MPOS - Gold Processing Operations crushing - primary/secondary grinding thickening-conditioning autoclaving neutralization leaching operations carbon stripping refining

9 MPOS CIMExcel Software Inc. Slide 9 MPOS - Operator Training - Control Room Displays

10 MPOS CIMExcel Software Inc. Slide 10 MPOS - Operator Training - Popup Controls

11 MPOS CIMExcel Software Inc. Slide 11 MPOS - Controls and Trends Display

12 MPOS CIMExcel Software Inc. Slide 12 MPOS - Additional Displays

13 MPOS CIMExcel Software Inc. Slide 13 MPOS - Training Scenarios

14 MPOS CIMExcel Software Inc. Slide 14 MPOS - Completely Configurable

15 MPOS CIMExcel Software Inc. Slide 15 MPOS – Completely Configurable

16 Stockpile - Feeders Model MPOS CIMExcel Software Inc. Slide 16

17 MPOS CIMExcel Software Inc. Slide 17 MPOS - Semi-Autogenous Mill Model

18 MPOS CIMExcel Software Inc. Slide 18 MPOS - Autogenous Mill Model

19 MPOS CIMExcel Software Inc. Slide 19 MPOS - Pebble Crusher Model

20 MPOS CIMExcel Software Inc. Slide 20 MPOS - Ball Mill Model

21 MPOS CIMExcel Software Inc. Slide 21 MPOS - Cyclone Model

22 MPOS CIMExcel Software Inc. Slide 22 MPOS - Flotation Model

23 MPOS CIMExcel Software Inc. Slide 23 Flotation Cell Level Dynamics Q air 1 Q in S in L1L1 V1V1 U1U1 Q air i LiLi ViVi UiUi Q air n ρnρn LnLn VnVn UnUn z1z1 zizi ρiρi ρ1ρ1 note, V i = valve position U i = valve positioner

24 Cyclones 5 -> 6 -> 4 -> 5, Air Flow - Flow Ratio Control, Solids Setpoint 50% Flotation Cell Level Dynamics open loop response MPOS CIMExcel Software Inc. Slide 24

25 MPOS CIMExcel Software Inc. Slide 25 time scale: 10 minutes per division, 100 minutes Flotation Cell Levels - Nonlinear Model Reference Modal Control feed flow dependent cell level setpoint mode

26 MPOS CIMExcel Software Inc. Slide 26 MPOS - Flotation Cell Level Dynamics and Control relative metal recovery efficiency = F f M m V v G g S s P p T t R r A a H h F = relative ore feedrate M = relative metal grade V = relative metal grade variability G = relative grind S = relative feed solids P = relative pH T = relative temperature R = relative reagents ratio A = relative air ratio H = relative froth height f, m, v, g, s, p, t, r, a, h are typically in the range of -1 to 1. relative grind = mining operations (blast pattern, charge, ore size, toughness), primary crushing (gap, feedrate), primary grinding (feedrate, steel, water, speed, load, power), secondary grinding circuit (cyclones, water, CFP speed, BM speed)

27 MPOS CIMExcel Software Inc. Slide 27 MPOS - Gold Leaching Operations - Dynamics and Control air 1 ρ1ρ air 2 air 3 air 4 air 5 air 6 air 7 air 8 W f1 Au f1 W f2 Au f2 W f3 Au f3 W f4 Au f4 W f5 Au f5 W f6 Au f6 W f7 Au f7 W f8 Au f8 W t2 Au t2 W t3 Au t3 W t4 Au t4 W t5 Au t5 W t6 Au t6 W t7 Au t7 W t8 Au t8 WcWc Au c WdWd Au d W cl W cp V1V1 V2V2 V3V3 V4V4 V5V5 V6V6 V7V7 V8V8 S f1 ρ2ρ2 ρ3ρ3 ρ4ρ4 ρ5ρ5 ρ6ρ6 ρ7ρ7 ρ8ρ8

28 MPOS CIMExcel Software Inc. Slide 28 MPOS - Process Units Primary and Secondary Crushers Primary and Secondary Crushers Stockpile Ore Quality Distribution Stockpile Ore Quality Distribution Apron and Pan Feeders Apron and Pan Feeders Ore Conveyors - Fixed and Variable Speed Ore Conveyors - Fixed and Variable Speed SAG / AG Mills - Wear, Steel, Ore, Water, Speed, Power, Load, DE Particle Size SAG / AG Mills - Wear, Steel, Ore, Water, Speed, Power, Load, DE Particle Size Screen Feed Pump Box - Level and Solids - Fixed and Variable Speed Pump Screen Feed Pump Box - Level and Solids - Fixed and Variable Speed Pump Screening - Particle Size Distribution Screening - Particle Size Distribution Grinding Mills - Lube Oil Systems Grinding Mills - Lube Oil Systems Pebble Crusher - Particle Size Distribution Pebble Crusher - Particle Size Distribution Ball / Rod Mill - Solids, Speed, Power, DE Particle Size Ball / Rod Mill - Solids, Speed, Power, DE Particle Size Cyclone Feed Pump Box - Level and Solids - Fixed and Variable Speed Pump Cyclone Feed Pump Box - Level and Solids - Fixed and Variable Speed Pump Cyclones - Mass Flows, Solids, Particle Size, and Partition Cyclones - Mass Flows, Solids, Particle Size, and Partition Cyclone Sets - Pressure, Solids and Flow Cyclone Sets - Pressure, Solids and Flow Flotation - Multi-Cell Level Dynamics Flotation - Multi-Cell Level Dynamics Flotation - FE Particle Size, Solids and Flow Flotation - FE Particle Size, Solids and Flow Flotation - Air and Reagents Addition and Metal Recovery Flotation - Air and Reagents Addition and Metal Recovery Tailings - Particle Size, Solids, Flow, and Sanding Tailings - Particle Size, Solids, Flow, and Sanding

29 MPOS CIMExcel Software Inc. Slide 29 MPOS - Conventional and Advanced Control Loops Lube Oil Systems Lube Oil Systems Apron and Pan Feeder Speed Apron and Pan Feeder Speed SAG / AG Mill - Feedrate SAG / AG Mill - Feedrate SAG / AG Mill - Power and Load SAG / AG Mill - Power and Load SAG / AG Mill - Water Ratio SAG / AG Mill - Water Ratio SAG / AG Mill - Speed SAG / AG Mill - Speed SAG / AG Mill - Water Addition SAG / AG Mill - Water Addition Screen Feed Pump Box Level Screen Feed Pump Box Level Pebble Crusher Pebble Crusher Cyclone Feed Pump Box Level Cyclone Feed Pump Box Level Cyclone Scheduling Cyclone Scheduling Cyclone Underflow Water Addition Cyclone Underflow Water Addition Cyclone Overflow Water Addition Cyclone Overflow Water Addition Cyclone Overflow Solids Cyclone Overflow Solids Ball Mill-Cyclone Circuit Grind Optimization Ball Mill-Cyclone Circuit Grind Optimization Multi-Line Ball Mill-Cyclone Circuit Optimization Multi-Line Ball Mill-Cyclone Circuit Optimization Flotation Cells - Nonlinear Multivariable Control Flotation Cells - Nonlinear Multivariable Control Flotation Air and Reagents Flotation Air and Reagents


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