from material balance to operational accounting...the role of data reconciliation and material...

From Material Balance to Metallurgical and Operational Accounting

Luis YacherSigmafine Users ConferenceSan Francisco, April 23, 2012

AGENDA

CONTEXT, the Overall Picture

The Role of Data Reconciliation and Material Balance

Data Reconciliation and Material Balance, AMIRA Reference Model

Data Reconciliation and Material Balance, Execution Fast Tour

The CORE, the Process Model

The CORE, the ENHANCED Process Model

The System Architecture

Met Accounting Implementation

SF in M&M

CONTEXT, Met. & Op. Accounting, the Overall Picture

Business Systems

Total Values

Avg, Cummulated

Production Stats.

Real vs. ProgramOperational KPI

Line/Area Values

Process Values

Consumables

?What isneeded in ?

Inventories

the gap?

Real time DataLab DataMine Systems DataEquipment Data

LevelsOre

CharacteristicsDown Times

PROCESS

FlowsAnalysis

CONTEXT, Met. & Op. Accounting, the Overall Picture

Business Systems

Total Values

Avg, Cummulated

Production Stats.


Line/Area Values

Process Values

Consumables

Operational ContextsData Validation Aggregation

Inventories

Functional contexts

Info. Workflow Mgmt.

Adjustments

Reconciliation

Calculations

KPI´s calcs


LevelsOre


PROCESS

FlowsAnalysis

The Role of Data Reconciliation and Material Balance

…just in one slide

For:For:

• Material Flows, Inventories and Analysis• Process Water, Water make-up, Inventories and

consumptions To get a single, To get a single, p• Effluents

From Mine to Port:

For every process area and line

g gobjective and shared version of the truth

g gobjective and shared version of the truth

• For every process area and line• For every critical process

HOW?HOW?

Starting from:• Real time Data• Lab Data

A formalprocedure to

That complies with the following basic principle:

what i

what t

Inventory 0+- =• Mine Systems Data• Equipment Data

get a set of data

goes in goes out variation


• DATA IS AN ASSET• DATA IS SHARED AND ACCESIBLE• DATA QUALITY IS FIT FOR PURPOSE• DATA QUALITY IS FIT FOR PURPOSE• DATA IS SECURE• DATA IS NOT DUPLICATED

(AMIRA P754)


BALANCEMET ACCOUNTING MODEL

DATAMANAGEMENT

REPORTING TRACEABILITY

Data Results Meta Data


Data Collection

Data Processing

Data Validation

Data PreFilteringCollection Processing ValidationPreFiltering

DATA MANAGEMENT MET ACCOUNTING MODEL

Error Identification

Errors Calculation

BALANCE

Close and Publish

Reconcilation Results Analysis

MET ACCOUNTING MODEL

Data ManagementData Reconciliation and Material Balance, AMIRA Reference Model

DATA COLLECTION (ENTRY)

DATA COLLECTION FROM VARIOUS SOURCES (SCADA, Plant Historian, LIMS)

PIAF – Data References (PI, SQL Queries, Ad‐Hoc queries)

AUDITABLE DATA ENTRY

• Manual Checks• Range Checking• Double entry and validationy


DATA PREFILTERING

• NO DATA AVAILABLE (Instrument maintenance Interface Error DCS Error etc )NO DATA AVAILABLE (Instrument maintenance, Interface Error, DCS Error, etc.)• Use the last value• Use the average for the last x‐values• Use signal from close meterg

PIAF – Analysis RulesPIAF Analysis RulesPIAF ‐ FormulasPI‐ACE


DATA PROCESSING

• AGGREGATE DATA• CALCULATE ESTIMATORS (VIRTUAL SENSORS)

PIAF – Analysis RulesPIAF ‐ FormulasPIAF FormulasPI‐ACE


DATA VALIDATION

• CHECK DATA BEFORE RECONCILIATION• CHECK DATA BEFORE RECONCILIATION• AUTHORIZED CHANGES

PIAF – Tools‐ Excel Add‐InnExcel Add Inn‐ Ad‐Hoc functions


ERRORS ID AND CALCULATIONS

DEFINE TOLERANCES BASED ON STATISTICAL ANALYSIS• DEFINE TOLERANCES BASED ON STATISTICAL ANALYSIS

Variogram Application

Metal BalanceData Reconciliation and Material Balance, AMIRA Reference Model

MET ACCOUNTING MODEL

• PRIMARY – SECONDARY ACCOUNTING MODELSPRIMARY SECONDARY ACCOUNTING MODELS• MODELING DIFFERENT PROCESS (Concentrators, Smelters, Refineries, Leaching, SX‐EW, etc.)• HANDLE MODEL CHANGES (Model Versioning)

SIGMAFINE – Templates and Elements

PROCESS BOOK Representation


RECONCILIATION

SOLVER FOR MASS AND ASSAYS ADJUSTMENTS SOLUTION• SOLVER FOR MASS AND ASSAYS ADJUSTMENTS SOLUTION

SIGMAFINE ALGORITHM

2Ν

)Rawi - Reconciledi

Absolute Tolerancei(ΣMinimize )Absolute Tolerancei(Σ

i = 1


RESULTS ANALYSIS

• ADJUSTMENTS REVIEWADJUSTMENTS REVIEW• GROSS ERROR DETECTION• BIAS DETECTION• IMBALANCE ANALYSIS

SIGMAFINE TOOLS

• Test1, Test2 statistical parameters for i bl d i ti l tivariable deviation evaluation

• Test3, Test4 statistical parameters for imbalance evaluation• Influence determination

Meter 18

-30.00

-20.00

-10.00

.00

• Influence determination

y = 0.7732x - 13.639-90.00

-80.00

-70.00

-60.00

-50.00

-40.00

-100.00 .00meter18 Linear (meter18)

Meter 8

650.00

700.00

750.00

Meter 11550.00

y = 0.6773x + 121.01400.00

450.00

500.00

550.00

600.00

350.00

400.00

450.00

500.00

600.00 700.00 800.00meter8 Linear (meter8)

y = 1.3984x - 196.99 y = 0.9556x - 15.071300.00

300.00 400.00 500.00 600.00

meter11 Linear (meter11) Linear (meter11)

SCM SFData Reconciliation and Material Balance, Execution Fast Tour

Shall be a “MET” user experience

EXECUTE

REVIEW (Audit)

CONFIGURE

17


SELECT (CREATE) A BALANCE CASESELECT (CREATE) A BALANCE CASE

18


Analysis Functions

Balance FunctionsRun and Publish Functions

19


DATA Check and Validation

20


QUALITY Balance Index

21


Initial ImbalancesInitial Imbalances (Overview)

22


Initial Imbalances (Detail)Initial Imbalances (Detail)

23

SCM SF – AnalysisData Reconciliation and Material Balance, Execution Fast Tour

DeviationsDeviations

24

SCM SF – Raw DataData Reconciliation and Material Balance, Execution Fast Tour

Reviewing the DataReviewing the Data

Escritorio SF – Auditoría ToleranciasData Reconciliation and Material Balance, Execution Fast Tour

Reviewing the TolerancesReviewing the Tolerances

26


A PI-AF(SF) model of:

• Process Flows• Flows characterizations• Inventories

• Measurements

• Sources of data

• Data processing methods

• Calculation RULES• Calculation RULES

• Balance RULES

The CORE, the ENHANCED Process Model

Met. Accounting Rules and Processes

Op. Accounting Rules and Processes

Base (SF-AF) Model

Reconciled (balanced) values of:

Base (SF-AF) Model


Context (Model) related values of:

• Program

Context (Model) related values of:

• Program

Processes Processes


• Material flows & Composition• Inventories & Composition

Water s ppl reco er se


• Material flows & Composition• Inventories & Composition

Water s ppl reco er se

• Target• Target

Context (Model) related values of:Context (Model) related values of:+• Water:supply-recovery-use-inventory.

Contextual reference to:

• Water:supply-recovery-use-inventory.

Contextual reference to:

• Key consumablesSteelEnergyReagents

• Key consumablesSteelEnergyReagents

+Traceability & Data Quality fit for purpose:

• Values from instrumentsV l f i t

• Real time and history of related measurements and lab data

• Real time and history of related measurements and lab data

Reagents

• Key asset KPIAvailabilityUse

Reagents

• Key asset KPIAvailabilityUse

• Values from inventory variation

• Values from the ERP

SCM SFThe System Architecture

M tData CollectionD t P Filt i OpMet

Accounting Rules & Processes

Data Pre FilteringData ProcessingData ValidationError Id and CalculationAnalysis Results

Op. Accounting Rules & Processes

SIGMAFINE

ocessesy

PI-AF ENHANCED MODELMetadata

PI LIMS OTHERS


Business Systems

Total Values

Avg, Cummulated

Production Stats.


Line/Area Values

Process Values

Consumables

Operational Contexts

Functional contexts

Data Validation

Adjustments

Aggregation

Calculations Functional contexts

Workflow

Adjustments

Reconciliation

Calculations

KPI´s calcs


Inventories

LevelsOre


PROCESS

FlowsAnalysis


Business Systems

Total Values

Avg, Cummulated

Production Stats.


Line/Area Values

Process Values

Consumables


Inventories

LevelsOre


PROCESS

FlowsAnalysis


Process Model Definition


Process Model Definition

Execution, validation and publishingpublishing procedures


Process Definitions Model Definitions

Model Analysis• Solvability • Redundancies • Consistency

PROJECT METHODOLOGY REFERENCEREFERENCE

Activity Site Responsible DeliverablesKickoff Meeting Customer Site SF - Customer - Scope

Functional Specs- Functional Specs.

System Platform and Infrastructure

Customer Customer - Prepared Infraestructure for the System

Data Gathering Documents

SF SF - Flowsheet Diagram- Data Gathering Spreadsheets- Data Gathering Spreadsheets

Data Gathering Customer Customer - Complete Data Gathering Spreadsheets

Preliminary Model and Redundancy Test

SF- One / two weeks in

SF - Preliminary Modely

customer site for Model adjustments

Prepare Data for Model Validation

Customer Customer - Data for Model ValidationModel Validation

Model Validation SF- One/two weeks in customer site for final model adjustments

SF - Model validated

adjustments

Model installation Customer Site SF - Customer - Model installed

SF in M&M

Copper-Moly Conc. Smelter Refinery Leaching SX/EWCopper MolyCodelco-North * * * * *Codelco-Andina *Codelco-Teniente * *Antofagasta Minerals-MLP *Xstrata&AngloCollahuasi * * *KUCC-Pilot * *

GOLD Conc. Leahing Carbon in Column

Merrill Crowe

Smelter

Plant XX (project in * * * * *progress)

SF in M&M

Xstrata&Anglo Collahuasi

Antofagasta Minerals-MLP

Fresh water supply, consumptions, water recovery

Luis [email protected]