Osvaldo Bascur

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Empowering Business in Real-time. Copyright 2010, OSIsoft LLC. All rights Reserved.

CONCENTRATOR DYNAMIC PERFORMANCE MONITORING:FLOTATION FRAMEWORK EXAMPLE

Osvaldo A. BascurOSIsoft, LCC

[email protected]


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AgendaOverview of the Mineral Processing

Needs

Forcing Factors and Key MarketDrivers

Dynamic Flotation Framework

Asset Framework Infrastructure

Dynamic Performance Management


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Ore Type 2

Ore Type 1

GRADE

RECOVERY

Optimize Efficiency

Optimize

Recovery and

GradeOptimize Recovery

Optimize Grade

GRADE RECOVERY MAP

Improving Metallurgical Performance


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Early work on Grinding/Flotation Integration, Copper 91.

Bascur,1991, Copper 91, TMS.


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5 Copyright 2010, OSIsoft LLC. Company Confidential.

Together into the new decade.

Access to Mining SCADA on line

Alumbrera, PI System Seminar, Buenos Aires 2001


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6 Copyright 2009, OSIsoft Inc. All rights Reserved.

Mining Grinding Flotation Dynamic

Performance Monitoring and Notification

Nelver Benavides et al, Southern Peru Copper, UC2010, www.osisoft.com

http://www.osisoft.com/Templates/item-

abstract.aspx?id=5120&type=events&cid=

1673&year=2010&industry=All&event=-1


7/287 Copyright 2009, OSIsoft Inc. All rights Reserved.

Profit Based Grinding Controls

Bascur, O.A., 1990, Profit-Based grinding controls, Minerals and Metallurgical Processing, February, pp. 9-15, SME


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Profit Based Grinding Controls, Virtual Sensors

Nelver Benavides et al, Southern Peru

Copper, UC2010, www.osisoft.com


9/28 Copyright 2010, OSIsoft LLC. All rights Reserved.9 Empowering Business in Real-time.

Dynamic Flotation Froth Experimental


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Flotation Variables Classification

Disturbances

Mineralogical Compositions

Uncontrolled Feed Rate

Uncontrolled Feed Size

Uncontrolled % Solids (pulp density)

Insoluble types

Surface modifications

Grade Variability

Manipulated Variables

Physical

Aeration

Impeller Speed Power

Pulp Level

Conditioning Time

Water Sprinkling Rate

Chemical

Reagent Additions (froth, Collectors,

Modifiers

Point Additions

Ph

Controlled

Recovery (tonnage)

Grade

Circulating Loads

Froth Levels

% Solids

Power Intensity

Measured Physical

Flow Rates

Bubbles Froth

Pulp Densities

Levels

Chemical Assays

Ph, Eh


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Flotation Cell Experimental Setup

Medidor de

Torque

Celdainstrumentada y

conectada a un

sistema

computacional para

la adquisicion dedatos y su control

Celda Denver

de un pie

cubico

modificada con

ventana de

vidrio,

Censores deespuma, nivel,

Muestrador de

espuma


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Flotation Cell Experimental Set up

Bascur, O.A., 1982, IMPC Toronto.


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Flotation Framework

Volume of liquidin the Froth

Volume of Bubblesin the Froth

Volume of Liquidin the Pulp

Volume of Bubblesin the Pulp

FeedQFeed

ijY TQLP

ijYATQ

BP

ijY

PAT

ijK

PDT

ijK

AirQBP

ijY

RQ

EQ

Pulp Phase

Froth Phase

ConcQLF

ijY

ACQ

BF

ijY

AirQ

FAT

ijK

FDT

ijK

LP

VLP

ij

YBP

VBP

ij

Y

LFVLF

ijY BFVBF

ijY

Qs

Two-Phase Flow

Critical Area

Entraintment

And

Drainage

Concentrate

TailingsFeed

Water Addition

Air


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Power, Water Recovery, Impeller Speed (RPM), Aeration and Frother Correlations


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Hydrodynamic Flotation Cell Profiles

Air Hold up vs Air Rate (Frother Concentration)


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Pulp Froth Interface detection


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Dynamic Froth and Pulp Volumes

.d V Froth(t)/.dt = QE + QW - QR - QC.d V Pulp(t)/.dt = Qfeed + QRQE - QT


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Water Hydrodynamics


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Example

Froth IV

DynaF-IV
http://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmvhttp://localhost/var/www/apps/conversion/OSI%20Users%202005/Australia/BubblesN1.EXEhttp://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmvhttp://localhost/var/www/apps/conversion/OSI%20Users%202005/Australia/BubblesN1.EXEhttp://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmvhttp://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmv


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PI AF 2.0Asset Templates

Data References Define Attributes

(PI Point, Table Lookup (RDB), Formula, User Written)

Attributes have Units of Measure

Common Template for each Asset Type

improves scalability for the enterprise


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28 Empowering Business in Real-time. Copyright 2010, OSIsoft LLC. All rights Reserved.

Analysis Framework for Grinding and Flotation

Operational Data, Ore Type, Hardness,

Viscocity, Separation index, TransportIndex, % Solids, Air Holdup, Flotation

and Thickener Hydrodynamics

Equipment Status Data

Running, Maintenance, Stopped, Down,

Troubles

Performance Metrics

Kwh/ton, Hours Running, Rec/Grade,

Tailings, Water Recovery,

Consumables, Balls, Reagents, Lime,etc. Min/Max/Stdev, Rate of Change,

Totals

By Process Line, Plant Area, Process

Equipment

For an hour, shift, day, week.


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29 Empowering Business in Real Time. Copyright 2010, OSIsoft LLC. All rights Reserved.

Cubos de datos

Unidad

Unidad 1

Unidad 3

Unidad 4

Unidad 2

Mineral 1

Mineral 2

Mineral 3

Mineral 4

Material

Tiempo

01:00 02:00 03:00

44.700

44.790

44.700

44.790

44.700

44.790

44.700

44.790

69.030

93.790

69.030

93.790

69.030

69.79069.030

69.790

42.7932

42.840

42.7932

42.840

42.7932

42.840

42.7932

42.840

85.132

85.980

85.132

85.980

85.132

85.980

85.132

85.980

94.110

94.85394.110

94.853

94.110

94.853

94.110

94.853

81.230

81.234

81.230

81.234

85.230

85.23485.230

85.234

Chancado

Flotacin

Molienda

Hidro

Proceso


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30 Copyright 2010, OSIsoft LLC. Company Confidential.Together into the new decade.

Example Concentrator OLAP


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Further Opportunities:

Integration of new measurements

Pulp Level Measurements

Accurate Reagent Addition

Power Measurements

Particle Size Distributions

Froth Cameras

Mineralogical Composition of Species (QEM*SEM)

Blast Characteristics

Improved Sampling and X-Rays Analyzers


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THANK YOU foryour attention

www.osisoft.com

Osvaldo Bascur

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