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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 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
CIMExcel Software Inc. Slide 4
Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization
CIMExcel Software Inc. Slide 5
OMPC Input - Output Variables
OMPC
MPOS CIMExcel Software Inc. Slide 6
MPOS - FAT and OTS installations for a large P2P site
MPOS CIMExcel Software Inc. Slide 7
MPOS - FAT and OTS for Metal ProcessingCopper and Molybdenum Processing Operations
MPOS CIMExcel Software Inc. Slide 8
MPOS - Gold Processing Operations
crushing - primary/secondary grinding
thickening-conditioning autoclavingneutralization
leaching operationscarbon stripping
refining
MPOS CIMExcel Software Inc. Slide 9
MPOS - Operator Training - Control Room Displays
MPOS CIMExcel Software Inc. Slide 10
MPOS - Operator Training - Popup Controls
MPOS CIMExcel Software Inc. Slide 11
MPOS - Controls and Trends Display
MPOS CIMExcel Software Inc. Slide 12
MPOS - Additional Displays
MPOS CIMExcel Software Inc. Slide 13
MPOS - Training Scenarios
MPOS CIMExcel Software Inc. Slide 14
MPOS - Completely Configurable
MPOS CIMExcel Software Inc. Slide 15
MPOS – Completely Configurable
Stockpile - Feeders Model
MPOS CIMExcel Software Inc. Slide 16
MPOS CIMExcel Software Inc. Slide 17
MPOS - Semi-Autogenous Mill Model
MPOS CIMExcel Software Inc. Slide 18
MPOS - Autogenous Mill Model
MPOS CIMExcel Software Inc. Slide 19
MPOS - Pebble Crusher Model
MPOS CIMExcel Software Inc. Slide 20
MPOS - Ball Mill Model
MPOS CIMExcel Software Inc. Slide 21
MPOS - Cyclone Model
MPOS CIMExcel Software Inc. Slide 22
MPOS - Flotation Model
MPOS CIMExcel Software Inc. Slide 23
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
MPOS CIMExcel Software Inc. Slide 24
MPOS CIMExcel Software Inc. Slide 25
time scale: 10 minutes per division, 100 minutes
Flotation Cell Levels - Nonlinear Model Reference Modal Controlfeed flow dependent cell level setpoint mode
MPOS CIMExcel Software Inc. Slide 26
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 CIMExcel Software Inc. Slide 27
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 CIMExcel Software Inc. Slide 28
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 CIMExcel Software Inc. Slide 29
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