CIMExcel Software Inc. Slide 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

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

MPOS CIMExcel Software Inc. Slide 3

MPOS - Operator Training - Control Room Displays


MPOS - Operator Training - Popup Controls


MPOS - Controls and Trends Display


MPOS - Additional Displays


MPOS - Training Scenarios


MPOS - Completely Configurable


MPOS - Semi-Autogenous Mill Model


MPOS - Autogenous Mill Model


MPOS - Pebble Crusher Model


MPOS - Ball Mill Model


MPOS - Cyclone Model


MPOS - Flotation Model


Flotation Cell Level Dynamics

Qair 1

Qin

Sin

L1

V1

U1

Qair i

Li

Vi

Ui

Qair n

ρn

Ln

Vn

Un

z1

zi

ρi

ρ1

note,

Vi = valve position

Ui = valve positioner


Flotation Cell Level Dynamicsd/dt V1 = A1 d/dt L1 = d/dt Va1 + d/dt Vp1

A1 d/dt L1 = d/dt Va1 + Qin - Q1out = d/dt Va1 + Qin - α1 f1(V1)(ρ1L1 + ρ1z1 - ρ2L2 )0.5

Ai d/dt Li = d/dt Vai + Qi-1out - Qiout = d/dt Vai + αi-1 fi-1(Vi-1)(ρi-1Li-1 + ρi-1zi-1 - ρiLi )0.5 - αi fi(Vi)(ρiLi + ρizi - ρi+1Li+1 )0.5

An d/dt Ln = d/dt Van + Qn-1out - Qnout = d/dt Van + αn-1 fn-1(Vn-1)(ρn-1Ln-1 + ρn-1zn-1 - ρnLn )0.5 - αn fn(Vn)(ρnLn )0.5

α1 , αi , αn constants. L1 , Li , Ln from bottom of tank. z1 = tank 1 – tank 2 elevations. zi = tank i - tank i+1 elevations. zn = 0.

Q1out = Qin + d/dt Va1 - A1 d/dt L1

= α1 f1(V1)(ρ1L1 + ρ1z1 - ρ2L2 )0.5

Q2out = Q1out + d/dt Va2 - A2 d/dt L2 = Qin + d/dt Va1 + d/dt Va2 - A1 d/dt L1 - A2 d/dt L2

Qiout = Qin + ∑j=1i (d/dt Vaj - Aj d/dt Lj)

= αi fi(Vi)(ρiLi + ρizi - ρi+1Li+1 )0.5

Qnout = Qin + ∑j=1n (d/dt Vaj - Aj d/dt Lj)

= αn fn(Vn)(ρnLn )0.5


Flotation Cell Level Dynamicssolids:τs1 d/dt S1 = Sin - S1

τsi d/dt Si = Si-1 - Si

τsn d/dt Sn = Sn-1 - Sn

solids time constant:τs1 = ρ1 V1 / ρin Qin

τsi = ρi Vi / ρs i-1 Qi-1

τsn = ρn Vn / ρs n-1 Qn-1

slurry density from solids:

ρs1 = ρore / ( S1 + (ρore/ρwater)(1 - S1) )Ρs i = ρore / ( Si + (ρore/ρwater)(1 - Si) )ρsn = ρore / ( Sn + (ρore/ρwater)(1 - Sn) )

cell density:

ρ1 = ρs1 (1 - f1 ) ρi = ρsi (1 - fi ) ρn = ρsn (1 - fn )


Flotation Cell Level Dynamicscell air:

f = void fraction

τar i = cell average rise time (s)affi = cell averaged void fraction - air flow factor

0.5 τar 1 d/dt f1 = aff1 Qain1 - f1

0.5 τar i d/dt fi = affi Qain i - fi

0.5 τar n d/dt fn = affn Qain n - fn

Vai = Vi fi = Ai Li fi

d/dt Va1 = 2 A1 L1 (aff1Qain1 - f1) / τar 1

d/dt Vai = 2 Ai Li (affiQaini - fi) / τar i

d/dt Van = 2 An Ln (affnQainn - fn) / τar n

Cyclones 5 -> 6 -> 4 -> 5, Air Flow - Flow Ratio Control, Solids Setpoint Control @ 50%

Flotation Cell Level Dynamics open loop response


Stockpile - Feeders Model



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 Ore Conveyors

• 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 Screen Feed Pump Box - Level and Solids

• Screening - Particle Size DistributionScreening - Particle Size Distribution

• Grinding Mills - Lube Oil Systems Grinding Mills - Lube Oil Systems

• Pebble Crusher - Particle Size DistributionPebble Crusher - Particle Size Distribution

• Ball / Rod Mill - Solids, Power, DE Particle Size Ball / Rod Mill - Solids, Power, DE Particle Size

• Cyclone Feed Pump Box - Level and Solids Cyclone Feed Pump Box - Level and Solids

• 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 - FE Particle Size, Solids and FlowFlotation - FE Particle Size, Solids and Flow

• Flotation - Air and Reagents Addition Flotation - Air and Reagents Addition

• Flotation - Metal Recovery Flotation - Metal Recovery

• Tailings - Particle Size, Solids, Flow, and Sanding Tailings - Particle Size, Solids, Flow, and Sanding


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 LoadSAG / AG Mill - Power and Load

• SAG / AG Mill - Water RatioSAG / 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 LevelCyclone Feed Pump Box Level

• Cyclone Scheduling Cyclone Scheduling

• Cyclone Underflow Water AdditionCyclone Underflow Water Addition

• Cyclone Overflow Water AdditionCyclone Overflow Water Addition

• Cyclone Overflow SolidsCyclone Overflow Solids

• Flotation Air and Reagents Flotation Air and Reagents

CIMExcel Software Inc. Slide 1

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