CIMExcel Software Inc. Slide 1 Mineral Processing Operations Simulator (MPOS) MPOS can be used for...

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


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 Factory Acceptance Testing - Configurations

Operator Interface

(simulated)

Standalone Interfaced to PCS HMI and Control Hardware/Software

DCS and MCC (simulated)

MPOS MPOS

PCS hardware /

software

PCSOperator Interface

MCC (simulated)

Control Device Outputs

Motor Status

DCS Analog Inputs

DCS Digital Inputs

Operator Training Scenarios Operator Training Scenarios

PID Setpoints and Modes

Motor Start/Stop

Process Variables

Motor Status

OPC-based Integration

PID Setpoints and ModesMotor Start/Stop

Process VariablesMotor Status

Control Device Outputs

Motor Status

DCS Analog Inputs

DCS Digital Inputs

Motor Stop/Start

Motor Status

PID Setpoints and Modes

Motor Start/Stop


Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization


OMPC Input - Output Variables

OMPC


MPOS - FAT and OTS installations for a large P2P site


MPOS - FAT and OTS for Metal ProcessingCopper and Molybdenum Processing Operations


MPOS - Gold Processing Operations

crushing - primary/secondary grinding

thickening-conditioning autoclavingneutralization

leaching operationscarbon stripping

refining


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 – Completely Configurable

Stockpile - Feeders Model



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

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

Flotation Cell Level Dynamics open loop response



time scale: 10 minutes per division, 100 minutes

Flotation Cell Levels - Nonlinear Model Reference Modal Controlfeed flow dependent cell level setpoint mode


MPOS - Flotation Cell Level Dynamics and Control

relative metal recovery efficiency = Ff Mm Vv Gg Ss Pp Tt Rr Aa Hh

F = relative ore feedrateM = relative metal gradeV = relative metal grade variabilityG = relative grindS = relative feed solidsP = relative pHT = relative temperatureR = relative reagents ratioA = relative air ratioH = 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)


MPOS - Gold Leaching Operations - Dynamics and Control

air1

ρ1

1 2 3 4 5 6 7 8

air2 air3 air4 air5 air6 air7 air8

Wf1

Auf1

Wf2

Auf2

Wf3

Auf3

Wf4

Auf4

Wf5

Auf5

Wf6

Auf6

Wf7

Auf7

Wf8

Auf8

Wt2

Aut2

Wt3

Aut3

Wt4

Aut4

Wt5

Aut5

Wt6

Aut6

Wt7

Aut7

Wt8

Aut8

Wc

Auc

Wd

Aud

Wcl

Wcp

V1 V2 V3 V4 V5 V6 V7 V8

Sf1

ρ2 ρ3 ρ4 ρ5 ρ6 ρ7 ρ8


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 SpeedOre 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 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, 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 PumpCyclone 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 DynamicsFlotation - Multi-Cell Level Dynamics

• Flotation - FE Particle Size, Solids and FlowFlotation - 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


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

• Ball Mill-Cyclone Circuit Grind OptimizationBall Mill-Cyclone Circuit Grind Optimization

• Multi-Line Ball Mill-Cyclone Circuit OptimizationMulti-Line Ball Mill-Cyclone Circuit Optimization

• Flotation Cells - Nonlinear Multivariable Control Flotation Cells - Nonlinear Multivariable Control

• Flotation Air and Reagents Flotation Air and Reagents

CIMExcel Software Inc. Slide 1 Mineral Processing Operations Simulator (MPOS) MPOS can be used for...

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