page 1 next generation software technologies using 3d emulation for the mining industry rev. 3.0
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Page 1
Next Generation Software TechnologiesNext Generation Software Technologiesusing 3D Emulation for the Mining Industryusing 3D Emulation for the Mining Industry
Rev. 3.0
Page 2
Who Are We ?Who Are We ?
Multidiscipline Dynamic Modeling & SimulationProducts and turnkey solutions provider for:
• Naval military sector• General industry
The products and services cover:• Process engineering,• Performance Analysis,• Real-time Control & Optimization• and Training Systems
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LiquidsLiquids GasesGases VentilationVentilation Electrical generation and distributionElectrical generation and distribution ControlsControls PropulsionPropulsion Cause & Effect and decisional logicCause & Effect and decisional logic
Our Products Modeling CapabilitiesOur Products Modeling Capabilities
Multidiscipline Dynamic Modeling & Simulation for:
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Requirements
Functionaland
Detailed Design
ConceptualDesign
ProductDefinition
DesignDesign
Our Products Application LifecycleOur Products Application Lifecycle
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Requirements
Functionaland
Detailed Design
ConceptualDesign
ValidatedSystems
Virtual Testing
ProductDefinition Performance
Analysis
AnalysisAnalysisandand
TestingTesting
Our Products Application LifecycleOur Products Application Lifecycle
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Requirements
Functionaland
Detailed Design
ConceptualDesign
OperationalSystems
TrainingSimulations
ValidatedSystems
Virtual Testing
ProductDefinition Performance
Analysis
Operator Operator TrainingTraining
Our Products Application LifecycleOur Products Application Lifecycle
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Real-time Control & Optimization Deployable
System
Requirements
Functionaland
Detailed Design
Re-fit and upgrades
ConceptualDesign
OperationalSystems
TrainingSimulations
ValidatedSystems
Virtual Testing
ProductDefinition Performance
Analysis
ControlControlandand
OptimizationOptimization
Our Products Application LifecycleOur Products Application Lifecycle
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Mine Ventilation OptimizationMine Ventilation Optimization““The Business Case”The Business Case”
• Ventilation = 35-50% of operating cost 35-50% of operating cost 1 – 30 M$ / year 1 – 30 M$ / year • Need to extract deeper ore bodiesdeeper ore bodies• Required energy increases exponentially • Often ventilation equipment is already maxed-outmaxed-out• Energy prices Energy prices continue to increaseincrease• Carbon emission Carbon emission costs may be added to financial statementsadded to financial statements• Aggressive energy management Aggressive energy management inevitable to remain
competitive• No compelling solution was available yetyet
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Mine Ventilation OptimizationMine Ventilation Optimization““The Solution”The Solution”
Expected benefits:Expected benefits:30 to 50+ % energy savings30 to 50+ % energy savings Improved air distribution where needed, when neededImproved air distribution where needed, when neededEnhanced safetyEnhanced safety
• Dynamic tracking Dynamic tracking of diesel machinery
• Ventilation calculation demanddemand for each of the mine work zones
• High fidelity modeling and simulation of the ventilation network
• Calculation of a real time mass balance real time mass balance for the ventilation network
• Control and optimization Control and optimization of air distribution and required electrical energy
• Setpoint optimization Setpoint optimization for all fans and airflow regulators
• Setpoints sent to the physical control devices via OPCOPC
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1. Engineering Suite2. OPC Server
1. GENESIS 322. DataWorX3. BridgeWorX
Mine Ventilation OptimizationMine Ventilation Optimization““The Iconics Integration”The Iconics Integration”
A turnkey solution that integrates A turnkey solution that integrates complementarycomplementary products products
4. GENESIS 645. WebHMI6. ReportWorX
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Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
Server
All information interchange
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Server
• Battery-powered wireless mesh network
• Dynamic tracking of machinerylocation and operating status
or
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
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Server
EngineeringSuite
A control system comprising:
•Dynamic ventilation demand calculation
•Physics based high fidelity ventilation network model
•Regulatory analog and logic controls
•Air flow optimizer
•Energy optimizer
or
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
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or
Server
EngineeringSuite
• Calculates ventilation demand from tracking information
• Model performs a real time mass balance
• Real-time results for flow, pressure, velocity and temperature
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
Smart P&IDsSmart P&IDs
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or
Server
EngineeringSuite
• Real-time analog and logic control
• Air flow and energy optimization
• Fans and air flow setpoints sent to PLCs via OPC
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
Control SchematicsControl Schematics
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Server
EngineeringSuite
Live MS-Excel link to simulation, controls and
optimizer.
or
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
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Server
EngineeringSuite
or
Dynamic and interactive performance analysis and tuning.
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
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PLCs
Bi-directional communication to PLCs and other external systems.
Covers communication redundancy.
Server
EngineeringSuite
or
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
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Server
EngineeringSuite
or
PLCs
provides the user
interface for surface operators.
WebHMI provides user interface to
underground miners.RerportWorX also provides system
operation, events and alarm reporting.
Mine Ventilation OptimizationMine Ventilation OptimizationFunctional ArchitectureFunctional Architecture
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PLCs
Server
EngineeringSuite
Mine Ventilation OptimizationMine Ventilation Optimization““The Next Generation”The Next Generation”
or
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Mine Ventilation OptimizationMine Ventilation Optimization““Smart P&IDs”Smart P&IDs”
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Mine Ventilation OptimizationMine Ventilation Optimization““Controls and Optimizer”Controls and Optimizer”
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Mine Ventilation OptimizationMine Ventilation Optimization““Excel as an Engineering Aid”Excel as an Engineering Aid”
Microsoft Excel Microsoft Excel dynamic dynamic link link to the simulation modelto the simulation model
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Mine Ventilation OptimizationMine Ventilation Optimization““Tracking”Tracking”
Tracking provides machinery Tracking provides machinery locationlocation and and operating statusoperating status
Ventilation demand Ventilation demand calculated calculated from the from the tracking resultstracking results
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Mine Ventilation OptimizationMine Ventilation Optimization““Tracking”Tracking”
Dynamic demand calculation Dynamic demand calculation based on trackingbased on tracking
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Mine Ventilation OptimizationMine Ventilation Optimization““Tracking”Tracking”
Dynamic demand calculation Dynamic demand calculation based on trackingbased on tracking
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Mine Ventilation OptimizationMine Ventilation Optimization““Control modes”Control modes”
• ManualManual; operator sets a fan speed or an air flow regulator opening position,; operator sets a fan speed or an air flow regulator opening position,
• Auto-CFMAuto-CFM; operator sets a desired CFM flow for a fan or air flow regulator,; operator sets a desired CFM flow for a fan or air flow regulator,
• Auto-VODAuto-VOD; optimizer calculates optimal required air flow as per results of ; optimizer calculates optimal required air flow as per results of the dynamic tracking.the dynamic tracking.
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Mine Ventilation OptimizationMine Ventilation OptimizationConclusionConclusion
This is more than “Control & Optimization”This is more than “Control & Optimization”
Challenge existing and new design performance through analysisChallenge existing and new design performance through analysis
Quickly evaluate alternativesQuickly evaluate alternatives
Test drive a designTest drive a design
Assist in adequate equipment sizingAssist in adequate equipment sizing
Validate mine expansion as planning toolValidate mine expansion as planning tool
Enable deeper mining with available ventilation resourcesEnable deeper mining with available ventilation resources
This solution is also applicable to other industries!This solution is also applicable to other industries!
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