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CIMExcel Software Inc. Slide 1 Performance Solutions for the Mineral Processing Industry Advanced Mineral Processing Control (AMPC) Mineral Processing.

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Presentation on theme: "CIMExcel Software Inc. Slide 1 Performance Solutions for the Mineral Processing Industry Advanced Mineral Processing Control (AMPC) Mineral Processing."— Presentation transcript:

1 CIMExcel Software Inc. Slide 1 Performance Solutions for the Mineral Processing Industry Advanced Mineral Processing Control (AMPC) Mineral Processing Operations Simulator (MPOS) Analysis and Engineering Services Throughput Increase % Recovery Increase %

2 AMPC CIMExcel Software Inc. Slide 2 Advanced Mineral Processing Control (AMPC) Increases Stability and Reduces Variability Increases Ore Throughput and Metal Recovery SAG / AG Mill Control and Optimization Cyclone Scheduling and Optimization Flotation Control and Optimization Integrated Conventional and Advanced Control

3 AMPC CIMExcel Software Inc. Slide 3 AMPC - Integrated Conventional and Advanced Control Conventional Control: Feeder Speed SAG / AG Mill Dual Power - Load Control SAG / AG Mill Speed SAG / AG Mill Water Ratio SAG / AG Mill Water Addition SAG / AG Mill Additives SFPB and CFPB Level Cyclone - Underflow and Overflow Water Addition Ball Mill Additives Flotation - Air Flow and Reagents Flow Lube Systems Temperature Advanced Control: SAG / AG Mill Feedrate, Water Ratio, and Speed SFPB and CFPB Level Lube Systems Temperature Cyclone Scheduling Cyclone - Overflow Solids Flotation - Air Flow and Reagents Flow

4 AMPC CIMExcel Software Inc. Slide 4 AMPC - Throughput Optimization Ore Quality Analysis and Feedforward Control Advanced Hill-Climbing Optimization Water Ratio Optimization Speed Optimization Ore Load Control Mode Feedrate and Power Constraints Mode Continuous Response Identification and Learning

5 AMPC CIMExcel Software Inc. Slide 5 AMPC - Advanced Hill-Climbing Optimization All trend windows herein display 100 minutes of operation.

6 AMPC CIMExcel Software Inc. Slide 6 AMPC - Throughput Optimization - Increased Throughput ~ 5 % A and B Primary Grinding lines are identical and are fed from the same stockpile. There are moderate variations in the stockpile ore quality. A-line has AMPC - Throughput Optimization active and averages 951 Tph. B-line has conventional dual power-load control and water ratio control active and averages 901 Tph.

7 AMPC CIMExcel Software Inc. Slide 7 AMPC - Ore Quality Feedforward Control The particle size distributions for the relative grinding time (RGT = 0.8, 1.0, 1.2) are determined from belt cut testing and correlation with the Ore Size Analyzer data. The realtime Ore Size Analyzer data is used to determine the current value of the Relative Grinding Time. The Relative Grinding Time, the current steel load, and the time from the last lifter/liner/grate rebuild are used to determine the Maximum Feedrate. AMPC uses the Maximum Feedrate value as the remote setpoint to the Feedrate Control Loop.

8 AMPC CIMExcel Software Inc. Slide 8 AMPC - Ore Quality Feedforward Control Ore Quality Feedforward Control provides very stable primary mill operation during moderately variable ore quality conditions.

9 AMPC CIMExcel Software Inc. Slide 9 Conventional Power-Load Control Loop For the conventional power-load control loop for the above primary mill power and load performance curves, the operator needs to enter a water ratio value (0.65), a power setpoint value (6700 kw), a load setpoint value (660 psi), a high power feeder cutback value (7100 kw), and a high load feeder cutback value (675 psi). These values are critical and determine the throughput and the operating stability of the primary mill. If feeder cutbacks are encountered - the operator will lower these values, if no feeder cutbacks have been encountered - the operator will raise these values.

10 AMPC CIMExcel Software Inc. Slide 10 AMPC - Ore Quality Feedforward Control In the above, A-line and B-line are fed from the same stockpile with moderately varying ore quality. A-line has Ore Quality Feedforward active and averages 962 Tph. B-line has Conventional Power-Load Control active and averages 652 Tph. There is a significant performance improvement with AMPC Ore Quality Feedforward Control.

11 AMPC CIMExcel Software Inc. Slide 11 AMPC - Recovery Optimization Cyclone Scheduling and Optimization Flotation Solids Control and Optimization Flotation (Air and Reagents) Feedforward Control

12 AMPC CIMExcel Software Inc. Slide 12 AMPC - Recovery Optimization - Increased Recovery ~ 2 % A1 and A2 Ball Mill - Cyclones - Flotation sides are identical and are fed equally from the same primary mill with the same particle size distribution. A1-side has AMPC - Cyclone Scheduling active, A2-side does not. Both sides have OF Density Optimization, Feedforward Air Ratio and Reagents Flow Ratio active. A1-side averages 89.8% recovery efficiency. A2-side averages 87.6% recovery efficiency.

13 Mineral Processing Operations Simulator (MPOS) Operator Training Facilities (for junior to senior operators) Control System Checkout Advanced Control System Design and Testing HMI Design and Testing Process and Equipment What-if Analysis Operator Training Facilities: Control Room HMI Displays and Inputs DCS/PLC Control System Motors Process Model - Accurate Operating Values and Dynamic Responses Operator Training Scenarios - Variations in Ore Quality and Failures of Equipment MPOS CIMExcel Software Inc. Slide 13

14 MPOS CIMExcel Software Inc. Slide 14 MPOS - Operator Training Facilities - Control Room Displays

15 MPOS CIMExcel Software Inc. Slide 15 MPOS - Particle Size Distributions - Stockpiles to Tailings

16 MPOS CIMExcel Software Inc. Slide 16 MPOS - Semi-Autogenous Mill Model

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

18 MPOS CIMExcel Software Inc. Slide 18 MPOS - Pebble Crusher Model

19 MPOS CIMExcel Software Inc. Slide 19 MPOS - Ball Mill Model

20 MPOS CIMExcel Software Inc. Slide 20 MPOS - Cyclone Model

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

22 MPOS CIMExcel Software Inc. Slide 22 MPOS - Comprehensive Operator Training Scenarios

23 CIMExcel Software Inc. Slide 23 Analysis Services Primary Crushing Operations - Ore Size Distribution and Variability Analysis Stockpile Ore Size Distribution Measurement, Classification and Grindability Analysis SAG / AG Mill Feedrate, Power, and Load Testing and Analysis SAG / AG Mill Speed and Water Ratio Testing and Analysis Pebble Crusher Performance Testing and Analysis SAG / AG Mill, Ball / Rod Mill, Pebble Crusher, Screening Particle Size Distributions (PSD) Screen Feed Pump Curves Cyclone Pack Pressure and Flow Curves Cyclone Overflow and Underflow Mass Flow and Solids Curves Cyclone Overflow and Underflow PSD Analysis and Partition Curves Ball / Rod Mill Power Draw Curves Flotation Feed Grade, PSD, Slurry Flow, Air Flow, Reagents Flows, and Recovery Analysis Tailings - Critical Particle Size and Sanding Rate Analysis

24 CIMExcel Software Inc. Slide 24 Engineering Services Instrumentation Requirements Signal Processing and Filtering Design and Testing OPC Connectivity and Integration Process Controllability and Variability Analysis Control Loop Functional Analysis, Design and Testing User Interface Functional Analysis, Design and Testing IEC 1131 Specifications, Programming and Testing DCS Checkout Support System Startup and Troubleshooting Support


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