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Desarrollo de Control de Procesos en Strata Cooper
Desarrollo de Control de Procesos en Strata Cooper
(McGill Professional Development Seminar Mineral Processing Systems) by P. Thwaites, May 15th, 2009
X Ni
X Cu
X Coal
XTS
X Alloys
X Zn
XPS
XT
XTS : Xstrata Technology Services Thras Moraitis - London XPS : Xstrata Process Support Frank McGlynn - Sudbury XT : Xstrata Technology Joe Pease - Brisbane
Opportunities to consider
Operational Performance Excellence requires a solid performance of the regulatory layer AND process optimisation. For Plant Operators: Is your feed stable? Are your instruments calibrated and performing? Are you aware of wireless instruments (including vibration)? Is your control system up to date and stable? Are you in manual or auto control? Are your Operators acting on alarms or are they nuisance? Do you understand and accept your process variability? Are you operating within the design targets and process constraints (pumps, cyclones, supplies, roasters, furnaces etc.)? Are you using your surge capacity, . or running tight level control? Are you at optimum and are the controls robust? Are you benefiting from asset management systems? Are failure / fault detection systems implemented? Can you make the same product for less energy consumption? (P. Thwaites, AUTOMINING2008, Chile)
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Plant Equipment
PLC/DCS
Strategies can then be formulated that eliminate these problems and thus improve availability.
* OEE Overall Equipment Effectiveness = Availability x Performance x Quality i.e. 100% = 100% x 100% x 100% OEE defines the expected performance of a machine, measures it and provides a loss structure for analysis, which leads to improvement.
(McKee, AMIRA P9L) Process control is a broad term which often means different things to different people. Process control is considered as the technology required to obtain information in real time on process behaviour and then use that information to manipulate process variables with the objective of improving the metallurgical performance of the plant. Control for the purpose of process improvement.
Audits
Audits are the first step to ensure control system investments meet expectations
(Feb. 1999 CONTROL ENGINEERING Journal, by Dave Harrold) Shown are the defects per loop e.g. Filter Time Constant Integral Period Derivative Period Sampling Period Proportional Band Current Operating Mode
45% 40% 35% 30% Frequency 25% 20%
16% 39% 34%
15% 10% 5%
0%
7% 4% 0%
2.
3. 4. 5. 6. 7.
Controls Auditing
Control Loop Optimisation Advanced Controls Slow Process Response Off-Gas System Controls Grinding Controls
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12
Mi n
er al
Sc ie
nc e
PROCESS MINERALOGY
al er in M si es oc Pr ng
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Staged crushing and screening prevents overproduction of fines Drill core or ROM 150mm rock at 150 kg/hr Blending technology produces RSD of < 5% in test charges
Any product size down to 1.7 mm split into any unit mass Semi-continuous operation
14
Commissioned 2005 11 campaigns to date Reproducible results Proven ability to mimic operations
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Finds optimum flowsheet, or finds best performance attainable with known flowsheet Montcalm Project - Type 1 Startup*
Montcalm start-up
100
80 Type 4 60
40
20
0 0 2 4 6 8 10 12 14
Montcalm start-up - October 2004
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19
units
As-builts (Commissioning)
higher production
setpoint
poor control
time
Falconbridge Limited - Process Control
Measure
Control
Optimize
Process constraint
higher production
units
setpoint
poor control
best control
time
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5 Essential Control Loop Elements & Consider the Whole Loop (ABB)
Advant OCS
Ramp rate Filter Deadband D/A
4-20 mA
A/D I/P
4-20 mA
3-15 psi
Filter
mV
Positioner
0-6 bar
Filter FT
Actuator
Only when all five elements are performing their best will the control system meet expectations!
* February 1999 CONTROL ENGINEERING by Dave Harrold.
ABB
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Regulatory Control improvements (AG Mill Bearing Pressure measurement) Careful: 1) Appropriate filtering; 2) PI Data compaction.
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25
Function
Cash Optimization Economics
Optimization
Advanced
Process
Optimize
Optimizing Control
Loop Control
Stabilize
Regulatory Manual
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Economic Return
Processes
Era of Quantity
Objectives
Tonnage of Concentrate
Control Technology
PLC or DCS
The evolution of control can be summarized in this slide. The first shift was from quantity only to quantity and quality, both applied in a DCS or PLC.
Quality
Peak Performance
However, to shift from maintaining quality to peak performance requires something more than a DCS or PLC: an optimizing control system.
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Cross-Coupled
Higher
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Non-linear
454 + S1 x + d
Enabling Technologies
(McKee, 1999). In grinding, control of AG/SAG mill circuits is the dominant area. While some systems have emerged which provide a reasonable level of control, there is still much not understood about the dynamic behaviour of these mills, and there is considerable scope for further development.
1. Multivariable Controller in a PLC Function Block (Bartsch): SAG feed control, is generally done using an Expert system. These systems often deliver improved control and 4 to 5% increased throughput (e.g. Collahuasi and Raglan Mills); XPS has recently implemented a complex controller in a (Concept) control block, negating the costs of an auxiliary Expert System, and training / support of this system.
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Flotation
21-CV-05
Cyc CycO/F O/F Density Density by by P/Boxwater water addition P/Box addition
DI
PI PIC
RSP
DIC
OUT
SY DI
H/L L im
FI
MIC
OUT
H/ L Lim
DIC
OUT
Ref: FTC Report Raglan: Cyclone De nsity Control, E. Bartsch, 11 Novemb er 2005
21-CV-02
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4500
Tonnage - mtph
4400
Time
In Cascade control (constant kPa), The SAG tonnage varies tremendously to maintain the requested setpoint.
SAG Feed SAG Load mpth kPa 131.3 4 454 9.7 24 100.5 4 392 152.7 4 503
SAG KPA
150
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160
140
120
Mill Power
100
80
60
40
20
0 1600 0 0.035 9/29/2002 9:30:00 AM TONNAGE ALIM.BROYEUR AUTOG PUISSANCE BROYEUR AUTOGENE PRESS. D'HUILE PALIER DECH Alimentation Moulin AG D75
9/29/2002 9:30:00 PM
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Outputs
(Set-points)
Fuzzyfication
Fuzzy Rules
De-fuzzification
Programmed in existing plant PLCs
Mill Speed
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Field Device
Mill Objectives *:
1. 2.
Increase the fineness of the grind to P80 = 75 Reduce Cyclone Feed Density to improve classification efficiency.
* Ref: Report Raglan Optimization Project : Raglan Site Visit L Urbanowski, Jan 14 2006
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LI
LIC
SY
DI DIC
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The feed density is slow to respond which means the loop cannot be tuned for load disturbance The influence of adding water changes depending on your mill capacity: A. spare grinding capacity it will trim the feed density as expected. B. at or over capacity -; it will increase circulating load and density, resulting in more water addition .
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Control water addition by using the more responsive process variable (overflow density). Consider the circulation load to avoid overloading the ball mill. Maximize circulating load in order to maximise mill efficiency. Filter measured variables appropriately (i.e. match the process response times)
Ref: FTC Report Raglan: Cyclone Density Control, E. Bartsch, 11 November 2005
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1
DI PI
1.
Control water by using the more responsive process variable (Cyclone Overflow Density). Use the output of the Cyclone Feed Density controller as the remote (ext.) set-point for Cyclone Overflow Density controller.
(This cascade is more suited to the slow dynamics of the loop.)
2. PIC
RSP OUT
DIC
LI
LIC
OUT
Select Logic
3
SY DI
H/L Lim
3.
FI
MIC
OUT
H/L Lim
OUT
DIC
Use a Circulating Load controller to either trim Feed Rate or Cyclone Feed Density setpoint. N.B. feed will
need adjusting if circulating load does not reach steady state.
2
Ref: FTC Report Raglan: Cyclone Density Control, E. Bartsch, 11 November 2005
4.
Filter appropriately
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130.0
120.0
% Circ
500
110.0
Load
400
100.0
90.0
P80 90
Circ Load Circ Load SP D80
microns
300
80.0
P80 80
microns
P80 68
microns
0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 February March
40.0
Reduced* p80 by 10 microns = 0.6% Ni rec increase worth approx. $2,000,000 pa.
(* ref feasibility study benchmarking 2004)
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- Cyclones (often) operating below their design pressure (40-60 instead of 100 kPa): Increased short-circuiting of water & undersized particles; IsaMill feed density decreases below design value; Low IsaMill feed density may create pumping issues (& trip on low flow/pressure); - Cyclone pressure should be controlled using the cyclone feed-rate. 43 - Implement Surge Tank Control (using 150 m3 of tank) NOT Tight Level Control.
Strathcona Mill Regrind Cyclone Overflow Density Results - 3 days operation (including startup)
Plot-0 350 50 CGCYCRBmv~C_PIC_2057:B_PID2057.MEAS 192.74 kPa CGCYCRBmv~C_DIC_2060:B_AIN2060_1.PNT 29.0277 % solids
300
250
200
150
100
Overflow Density:
50 0 20 1/18/02 7:16:18 PM B REG CYC PRESSURE B REG CYC O/F DENSITY 3.00 Day(s)
Plot-0 350 50
300
Improved startup
250
200
150
100
50
3.00 Day(s)
3/24/02 7:16:18 PM
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Enabling Technologies
2. On-Demand Sampling Automation:
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Enabling Technologies
3. Camera Imaging, flotation level & reagent controls
Feed size analysis; Froth camera imaging; Optical System for cathode quality:
CSQA: Cathode Surface Quality Analyzer (Aplik)
Froth Camera Imaging Technology
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If we look at the energy efficiency we find that three aspects are critical: 1. Air dispersion 2. Rotational speed of the mechanism 3. Component wear
Optimal air dispersion is one of the basic requirements for good metallurgical performance. Plants operating with forced air cells have often noticed that the best results are achieved using individual and varying air feed rate in each cell.
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48
49
Froth Velocity
1. Velocity (mass pull) changes by over 1000%! 2. Baseline pull is only 0.5 1 cm/s! : Level SP too low?
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SP Aire
SP Velocidad
PV Velocidad
SP Nivel
Tapon
Celda WEMCO
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Rougher flotation
Test Control strategy step1
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Froth veloc.
Level SP
Air SP
Tails %Ni
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All of the Met. Loops are PI/PID controllers for supportability. If problems occur, operators may turn off one level of control at a time, independently for each reagent.
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None of the above measurements are trivial and require attention to equipment selection and installation.
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Shown is an E&H Deltabar S smart (2 wire) differential pressure transmitter. It is ideally used to measure level, pressure or differential pressure. Uses a flush mounted ceramic diaphragm since they out last the metallic diaphragms by at least 10 years.
(Ref. M. Gribbons)
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Enabling Technologies
4. Flow Measurement: SONAR A New Class of Meters with Distinct Application Advantages
Ref: Christian OKeefe
cokeefe@cidra.com
Multivariable DP
Vortex
Ultrasonic
SONAR
Magmeter
Coriolis
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5 .0 %
16000
4 .5 %
14000
4 .0 %
3 .5 %
12000
3 .0 %
10000
2 .5 %
8000
2 .0 %
6000
1 .5 %
4000
1 .0 %
2000
0 .5 %
0 1 /2 5 /2 0 0 6 4 :4 8 :0 0
1 /2 5 /2 0 0 6 6 :0 0 :0 0
1 /2 5 /2 0 0 6 7 :1 2 :0 0
1 /2 5 /2 0 0 6 8 :2 4 :0 0
0 .0 % 1 /2 5 /2 0 0 6 9 :3 6 :0 0
T im e
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Enabling Technologies
5. Rotating Equipment Machinery Health:
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Enabling Technologies
6. Wireless Instrumentation:
HighService
INDUSTRIAL SUPPORT COMPANY
RF Transmitter,
Sensor Life: 18 month
GITE-322-05-PRE-15
GITE / DES
60
Density
61
D e n s it y
62
Process Modeling
Step R esponse 0.8 0.7
0.6
10 s
0.5
0.4
0.3
0.2
0.1
0 0
500
1000
1500 Tim e
2000
2500
3000
Step R esponse 0
-0.02
-0.04
15s
-0.06
-0.08
-0.1
-0.12
-0.14
-0.16
-0.18
-0.2 0
100
200
300
400
500 Tim e
600
700
800
900
1000
11
Process Modeling:
Input and output signals 80
M e asu red and sim u late dm o del outp ut
70
15
Two SISO, simple PI controllers: 1. Cyclone Over Flow Density (COFD) by manipulating the Pump-Box Water (PBWsp) 2. Rod Mill Feed (RMFsp) based on the Pump-Box Level (PBLsp)
y1
60
10
50
5
40 0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0
180
140
50 00 T im e
10 000
15 000
1000
2000
3000
4000
5000 Tim e
6000
7000
8000
9000
10000
170
-5
160
-10
u1
150
-15 0
145
140 135 u1 130 125 120 115 0 500 1000 1500 Tim e 2000 2500 3000 3500
-1
-2
63
64
65
66
11
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55 45 35 25 15 RMWi
V ariable RM Wi RM F S P T (t/h)
Key Results
(Over a Longer Period)
Period: (Jan.07-May.08 vs Jun.08-Sept.08)
Date
Increase in circuit throughput of 7.7%: (168 to 181 tph); fully realised upon treatment of Ni Rim South ore; Grinding circuit feed to flotation (COFD) maintained at target density: reduction in variability from 2.0 to 0.8; An increase in energy efficiency (kW/t) of: 7.1% for the rod mill and 7.5% for the PBM; No Mill overloads; No degradation in Ni or Cu Recoveries.
0.060 Density 0.045 0.030 0.015 0.000 156 162 168 174 180 RMF SPT (t/h) 186 192 198
COFD (%)
50
40
30 01/10/07 03/01/07 04/14/07 06/08/07 07/29/07 10/02/07 Date 12/09/07 02/25/08 04/18/08 06/13/08 09/24/08
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Feedback Comments
Operators:
This has made the operations of the mills that much easier and efficient!DD It is working great and it is helping flotation as well. RA This is better and the right way to do it. SH To do better than the controller, I have to take samples every 15 minutes. BR I thought this will not work, but it is working very well. JM
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Soft Sensors
30
FeO
25
20
15
10 0
20
40
60 Sample No.
Valve position
SPE
20 15 10 5 0
20
40
60
80
100
120
140
160
180
Time
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Concluding Remarks
Plant automation is often seen as the project deliverable, when what is really required is plant control. There are many approaches, instrumentation, and multiple control systems, together with numerous advanced control packages to select from. Process control is more than just tools. Successful plant implementation is reliant on these together with:
process knowledge, a solid control engineering background / experience, and the operations team willing to act / implement / support the implementations.
Together, robust solutions can be realised, minimising process variation and optimising process performance.
This will result in an easier, efficient and safer process to operate.
At previous (high) metal prices the results from good control, and Operation Performance Excellence are substantial! At current metal prices good control and Operational Performance Excellence is essential! Operational Performance Excellence requires a solid performance of the regulatory layer AND process optimisation. Organizational structure and human resources are important in achieving Operational Performance Excellence. Thank you.
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