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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. - PowerPoint PPT Presentation

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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 CIMExcel Software Inc. Slide 4

MPOS - Operator Training - Popup Controls

MPOS CIMExcel Software Inc. Slide 5

MPOS - Controls and Trends Display

MPOS CIMExcel Software Inc. Slide 6

MPOS - Additional Displays

MPOS CIMExcel Software Inc. Slide 7

MPOS - Training Scenarios

MPOS CIMExcel Software Inc. Slide 8

MPOS - Completely Configurable

MPOS CIMExcel Software Inc. Slide 9

MPOS - Semi-Autogenous Mill Model

MPOS CIMExcel Software Inc. Slide 10

MPOS - Autogenous Mill Model

MPOS CIMExcel Software Inc. Slide 11

MPOS - Pebble Crusher Model

MPOS CIMExcel Software Inc. Slide 12

MPOS - Ball Mill Model

MPOS CIMExcel Software Inc. Slide 13

MPOS - Cyclone Model

MPOS CIMExcel Software Inc. Slide 14

MPOS - Flotation Model

MPOS CIMExcel Software Inc. Slide 15

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

MPOS CIMExcel Software Inc. Slide 16

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

MPOS CIMExcel Software Inc. Slide 17

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 )

MPOS CIMExcel Software Inc. Slide 18

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

MPOS CIMExcel Software Inc. Slide 19

Stockpile - Feeders Model

MPOS CIMExcel Software Inc. Slide 20

MPOS CIMExcel Software Inc. Slide 21

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 CIMExcel Software Inc. Slide 22

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

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