phelps dodge smelter realized cost savings and increased revenues with osisoft’s pi system...
TRANSCRIPT
Phelps Dodge Smelter Realized Cost Savings and Increased Revenues with OSIsoft’s PI
System
Vladimir Ushakov & Scott Voltura
Phelps Dodge Miami Inc.
OSIsoft User ConferenceMay 12-14, 2003
San Francisco
May 12-14, 2003 Slide 2
Communication Architecture
LAN
Data Highway
LCN
History Module
server
PI Server with RAID5server
Application Serverscomputer
group
Users PCs - PI clients with Win95 and W2K machines
Ethernet
Scanner 2. Gateway between LAN and Environmental Data highway
Scanner 3. Gateway between LAN and Honeywell DCS Local Control Network (LCN) Data highway
Scanner 1. Gateway between LAN and Smelter (PLC) Data highway
Data Highway
May 12-14, 2003 Slide 3
Smelter General Schematic
Bedding PlantISA Vessel
Matte Grade = 55
Oxygen Enrichment = 40% Flow = 438 SCFM
Blast Air Avg = 28,600 Flow
=40 SCFM
Natural Gas Flow =70 SCFM
Silica Flux =4.4 dstph
Reverts
Scrap Copper = 15 stpd
Converter Slag Return
Converter Slag Return
Electric Furnace Matte
= 1,064.6 stpd
No. 2 Anode Vessel
Mold Cast Vessel
Scrap Copper
Reverts Avg = 4.4 dstph
Silica Flux Avg = 6.3dstph
Copper Concentrate 85.7
dstph
Resource Recycling Material
3.3 dstph
Bedded Material Day Tank
ISA Lance
No.5 Converter
No.4 Converter
Anode Casting Wheel
No. 1 Anode Vessel
ELECTRODES
ELF Slag Grade = 0.7
To Slag Dump 1,473.6 stpd
Total Copper Anodes
Production =624.6 STPD
ACID PLANT
Sulfur Capture = 97.6%Avg Production = 1,868 stpd, 93%
H2SO4
NOTE: All data are from the the Process Design Criteia
PHELPS DODGE MIAMI INC. SMELTER PROCESS FLOWCHART
Operating Days per Year = 351
3 BEDS @ 6,500 Tons each
Dust Recycle0.4 dstph
Offgas42,2000 scfm
Matte = 1178.4 stpdSlag = 1,015.2 stpd Matte
Grade = 57.85
Offgas10,165 scfm
Anode Scrap = 35 stpd
OffgasSlag Blow =35,000 scfm
@6.8%SO2Matte Blow = 36,000 @7.3% SO2
Blister Copper = 676.4 stpd
Reverts
Silica Flux
Reverts
Silica Flux Silica Flux
Mercury Recovery Plant
Mercury to Outside Customer
Solids
ELF
No.3 Converter
No.2Converter
May 12-14, 2003 Slide 4
PI Server Considerations
• We are a Microsoft shop.
• PI was installed in 1999.
• Collecting data for almost 5000 points.
• Excel, Access and MS SQL as enterprise-wide data storing/manipulating engines.
• Use PI-DataLink for Excel to display values for PI tags.
May 12-14, 2003 Slide 5
PI Uses
• Predictive/Preventative Maintenance.
• Capital Expenditure Justifications.
• Six Sigma Initiatives.
• Failure Analysis.
• Trouble Shooting.
• Audit Operator’s Decision Making Rationale.
May 12-14, 2003 Slide 6
Molten Metal Level to Control
Opportunity to control demand/supply of primary product – copper.
May 12-14, 2003 Slide 7
Rationale For Application
• Operators used field input and applied a rule of thumb to determine necessary production levels. High losses incurred due to unbalanced demand/supply.
With PI server:1. Powerful data storing/retrieving tool. 2. Conveniently incorporates into MS Office3. Data displayed in real time – reduced error in
verbal communication and enhanced accuracy of demand/supply computations.
May 12-14, 2003 Slide 8
Daily Plan
May 12-14, 2003 Slide 9
GUI Design and Business Logic
• Not overloaded with unnecessary features.
• Based on the users’ input and suggestions.
• Retrieves values for 26 main parameters used for planning purposes.
• Business rules in Visual Basic, which allows communication to seamlessly flow among MS Office Applications.
May 12-14, 2003 Slide 10
Demand/Supply Application
May 12-14, 2003 Slide 11
Demand/Supply Application
• Displays the status of product availability, predicts demand and then balances supply.
• Communicates with PI server and Daily Plan to retrieve values for nearly 3 dozen critical parameters.
• Posses a dynamic character due to nature of the business and requires a periodic fine-tuning activity.
May 12-14, 2003 Slide 12
Year Generation Consumption Skims Percent Cu
2001 8,092 tons 776,692 tons 426 4.51 %
2002 4,713 tons 853,458 tons 407 2.57 %
Delta 3,379 tons 76,766 tons 19 1.94 %
42 % 10 % 4% 43 %
Savings $ 43,000
Revenue $ 200,000
Total $ 243,000
Financial Outcomes
May 12-14, 2003 Slide 13
Summary• These PI-DataLink applications enable
operators to understand the current status of the product demand/supply.
• Creates a tool to allow fine-tuning of the operating parameters which has reduced copper losses.
Future plans: - To Integrate various MS Office features such
as the automatic notification generation. - Improve GUI by migrating to Web applications.
May 12-14, 2003 Slide 14
Thanks for Your Attention!
May 12-14, 2003 Slide 15