cimexcel software inc. slide 1
DESCRIPTION
CIMExcel Software Inc. Greg Yorke , Ph.D, P.Eng. Control Systems Engineering Company located in Vancouver Modeling, Simulation, Control and Optimization Nuclear, Pulp and Paper, Power, Energy, and MMM Industries. MMM Industry: - PowerPoint PPT PresentationTRANSCRIPT
CIMExcel Software Inc. Slide 1
CIMExcel Software Inc.
• Greg Yorke , Ph.D, P.Eng.
• Control Systems Engineering Company located in Vancouver
• Modeling, Simulation, Control and Optimization
• Nuclear, Pulp and Paper, Power, Energy, and MMM Industries.
• MMM Industry:
> Highland Valley Copper – DCS MPOS – Checkout Simulator
> Highland Valley Copper – MPOS - Operator Training Simulator
> Gibraltar Mines – OMPC SAG Mill Control – Advisory Control Mode
• Schneider-Electric – CIMExcel Software OMPC-MPOS Agreement
CIMExcel Software Inc. Slide 2
OMPC-MPOS Agreement
Schneider-Electric – CIMExcel Software
• Expected Agreement Completion time ~ 3 months
• MMM Solutions – Centre of Excellence (Vancouver)
( 3 to 4 engineers in first year )
• MMM Software and Services Solution, plus electrical equipment
• OMPC Trial Use Project
• Comprehensive Support Contract
> OMPC Pit to Plant Optimization
> MPOS Pit to Plant - Operator Training Simulator
> On-site and remote monitoring, coaching, and optimization
(for operators, engineers, and managers)
CIMExcel Software Inc. Slide 3
OMPC – MPOS Performance Solutions for the Mineral Processing Industry
• Optimal Mineral Processing Control (OMPC)
• Mineral Processing Operations Simulator (MPOS)
• Analysis and Engineering Services
Throughput Increase 3 - 5 % Recovery Increase 1 - 3 %
CIMExcel Software Inc. Slide 4
Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization
CIMExcel Software Inc. Slide 5
Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization
• Increases Stability and Reduces Variability. • Increases Ore Throughput and Metal Recovery.
Increased Throughput 3 - 5 % Increased Recovery 1 - 2 %
CIMExcel Software Inc. Slide 6
OMPC Input - Output Variables
OMPC
OMPC CIMExcel Software Inc. Slide 7
OMPC - Increased Ore Throughput ~ 5%
A and B Primary Mills are identical and are fed equally from the same stockpile.
A-line has OMPC turned on, B-line does not. A-line averages 951 Tph. B-line averages 901 Tph.
OMPC CIMExcel Software Inc. Slide 8
OMPC - Increased Metal 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 distributions.
A1-side has OMPC - Cyclone Scheduling turned on, A2-side does not.Both sides have OF Density Optimization, Feedforward Air Ratio, and Reagents Flow Ratio turned on.
A1-side averages 89.8 % recovery efficiency.A2-side averages 87.6 % recovery efficiency.
OMPC CIMExcel Software Inc. Slide 9
OMPC - Integrated Conventional and Advanced Control
Conventional Control (implemented in DCS/PLC via ST):
• Ore Quality Analysis• Feeder Speed• SAG / AG Mill Dual Power - Load Control with Feedforward Ore Quality - discrete time • SAG / AG Mill Speed• SAG / AG Mill Water Ratio• SAG / AG Mill Water Addition• SFPB and CFPB Level• Cyclone - Underflow and Overflow Water Addition• Flotation - Air Flow and Reagents Flow• Lube Systems Temperature (with Feedforward)
Advanced Control (external PC via OPC):
• Feeder Modal Control• SAG / AG Feedrate, Water Ratio, and Mill Speed • Cyclone Scheduling • Cyclone - Overflow Solids• Flotation - Air Flow and Reagents Feedforward• Flotation Cell Levels - Multivariable Nonlinear Model Reference Modal Control with Feedforward and Dynamic Observer
OMPC CIMExcel Software Inc. Slide 10
OMPC - Primary Mill Control• Ore Quality Analysis and Feedforward Control for Feedrate, Solids, and Speed • Short-term Ore Quality Stabilization• Feeder Modal Control• Advanced Hill-Climbing Optimization for Feedrate, Solids, and Speed• Overload Prediction and Prevention• Grindout Optimization• Ore Load Control Mode • Feedrate Rate of Change Optimization• Feedrate and Power Constraints Mode• Dynamic Grinding Rate Model • Continuous Response Identification and Learning
OMPC CIMExcel Software Inc. Slide 11
OMPC – Primary Mill Control and Optimization
Advanced Hill-Climbing
Feedraterate of change
constraints
FeederModal
Control
Short-term Ore Quality
Stabilization
Overload Prediction GrindingRate Model
FeederSpeed
Controllers
Power-Feedrate Constraints
Ore Quality Analysis
Ore Quality Feedforward
Ore LoadControl
GrindoutOptimization
Identificationand Learning
Primary Mill Water Flow
Setpoint
Primary Mill Speed
Controller
SolidsOptimization
SpeedOptimization
OMPC CIMExcel Software Inc. Slide 12
OMPC - Ball Mill - Cyclones - Flotation Control
• Ball Mill Solids - Cyclone Scheduling Hill-Climbing Optimization
for Flotation Solids and Grinds
• Flotation Flow - Flotation Air and Regents Ratio - Recovery Efficiency Analysis
(at constant Flotation Solids and Grinds)
• Overall Recovery Efficiency Analysis and Optimization
• Flotation Air and Regents Ratio Feedforward Control
• Multi-line Ball Mill - Cyclone Hill-Climbing Optimization
• Ball Mill Overload Prediction and Prevention
• Comprehensive Constraints
• Cell Levels - Multivariable Non-linear Model Reference Modal Control with
Comprehensive Feedforward and Dynamic Observer
Cyclones 5 -> 6 -> 4 -> 5, Solids in MANUAL Control, Air Flow in Flow Ratio Control
Flotation Cell Levels - Non-linear Model Reference Modal Control
OMPC CIMExcel Software Inc. Slide 13
CIMExcel Software Inc. Slide 14
Optimal Mineral Processing Control (OMPC) - Features
• Conventional PID with Feedforward Control
• Discrete-time Control
• Non-linear Model Reference Control
• Modal Control
• Advanced Hill-Climbing Optimization
• Continuous Response Identification and Learning
• Model-based Virtual Measurements
• Advanced Signal Analysis and Process Variable Filtering
• Accurate Dynamic Models for Design and Testing
• Implemented in a DCS and a PC (via OPC)
CIMExcel Software Inc. Slide 15
OMPC Pit-to-Plant Optimization Variables
• Drill Hardness, Blast Pattern, and Powder Factor Tracking
• Primary Crusher Discharge Ore Size Distribution
• Primary Mill Feeder Ratios
• Primary Mill Feedrate
• Primary Mill Feedrate - Rate of Change
• Primary Mill Solids and Speed
• Primary Mill Steel Charge and Size (long term)
• Ball Mill Steel Charge and Size (long term)
• Ball Mill Solids and Speed
• Flotation Solids and Grinds
• Flotation Air and Reagents Ratios and Cell Levels
CIMExcel Software Inc. Slide 16
OMPC Pit-to-Plant Optimization - Manipulated Variables
• Blast Pattern and Powder Factor (long term)
• Primary Crusher Gap
• Feeder Speeds
• Feedrate and Rate of Change
• Primary Mill Solids
• Primary Mill Speed
• Cyclone Scheduling (Active Cyclones)
• Cyclone UF and OF Water Addition
• CFPB Water Addition
• Flotation Air Flow and Reagents Valves
• Flotation Cell Level Valves
OMPC CIMExcel Software Inc. Slide 17
OMPC – Other Features
• Primary Crusher Performance Analysis
• Primary Mill Performance Analysis
• Ball Mill - Cyclones Performance Analysis
• Flotation Performance Analysis
• Primary Mill Dynamic Response Model
• Conventional DCS PID Control Loops with Feedforward
• Discrete-time Control Loops
• Primary Mill Dual Power-Pressure Control with Ore Quality Feedforward
• Stockpile - Feeders Ore Size Classification Identification
• Primary Mill Design/Equipment Performance Improvement Analysis
(feed, steel, lifters, liners, grate, motors)
Pit Blasting and Primary Crusher Operations
OMPC CIMExcel Software Inc. Slide 18
OMPC CIMExcel Software Inc. Slide 19
OMPC - Ore Quality Feedforward Control
The particle size distributions for the relative toughness (RT = 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 Toughness.
The Relative Toughness, the current steel load, and the time from the last lifter/liner rebuild are used to determine the Maximum Feedrate.
OMPC uses the Maximum Feedrate value as the remote setpoint to the Feedrate Control Loop.
OMPC CIMExcel Software Inc. Slide 20
OMPC - Primary Mill Performance Analysis
OMPC CIMExcel Software Inc. Slide 21
Optimal Mineral Processing Control (OMPC) - Primary Mill Analysis and Optimization
OMPC CIMExcel Software Inc. Slide 22
Optimal Mineral Processing Control (OMPC) Advanced Hill-Climbing Optimization
Optimal Mineral Processing Control (OMPC) Feeders Modal Identification
OMPC CIMExcel Software Inc. Slide 23
Optimal Mineral Processing Control (OMPC) Feeders Modal Control
OMPC CIMExcel Software Inc. Slide 24
OMPC CIMExcel Software Inc. Slide 25
OMPC – Recovery Optimization
• Cyclone Scheduling and Optimization
• Flotation Solids Control and Optimization
• Flotation (Air and Reagents) Feedforward Control
• Flotation Levels – Multivariable Nonlinear Model Reference Modal
Control with Comprehensive Feedforward and Dynamic Observer
OMPC CIMExcel Software Inc. Slide 26
OMPC - Model-based Virtual Measurements
• Ore Quality
• Primary Mill Ore Discharge Rate
• Cyclone Size Partition
• Flotation Solids
OMPC CIMExcel Software Inc. Slide 27
OMPC - Ore Stockpile - Multiple Feeders Material Transport Model
OMPC CIMExcel Software Inc. Slide 28
OMPC – SAG / AG Mill Control and Optimization
OMPC CIMExcel Software Inc. Slide 29
OMPC - SAG / AG Mill Advisory Control Mode
OMPC CIMExcel Software Inc. Slide 30
OMPC – Ore Quality Analysis
OMPC CIMExcel Software Inc. Slide 31
OMPC – Pit-to-Plant Ore Size Reduction
OMPC CIMExcel Software Inc. Slide 32
OMPC – Primary Mill Ore Size Reduction Model
OMPC CIMExcel Software Inc. Slide 33
OMPC – Ball Mill – Cyclone Models
OMPC CIMExcel Software Inc. Slide 34
OMPC – Primary Mill Performance Analysis
OMPC CIMExcel Software Inc. Slide 35
OMPC - Pebble Crusher Models
Flotation Cell Levels - Non-linear Model Reference Modal Control
Qslurry in
÷ fi-1()
HysteresisCompensator
valve position
Vj
Feedforward
Dynamic Observer
PI
actuator positioner
Uj
Level Setpoints
• Operator Fixed• Feed Dependent• Startup/Shutdown
Leveli
Qair i
Solidsin
Leveli
Qair i
Li
+
-
++
OMPC CIMExcel Software Inc. Slide 36
Cyclones 5 -> 6 -> 4 -> 5, Solids in MANUAL Control, Air Flow in Flow Ratio Control
Flotation Cell Levels - Non-linear Model Reference Modal Control
OMPC CIMExcel Software Inc. Slide 37