Water and Energy Balances in

Mineral Processing Plants

Osvaldo Bascur and Ales Soudek

© 2008 OSIsoft, Inc. | Company Confidential

Introduction
z Water - Scarcity (Chile, Australia)
z Energy - Expensive 5.8 m3H20/ Ton Cu fino.

– Energy Price Volatility 1 m3 ton de Conc.

z Enterprise Energy and Water Management

– Management of corporate energy consumption is
essential for carbon management program and
initiatives
– Metal Loss Management
z Role of Mass and Energy Balances

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PI Value Drivers in Mining and Metals
How to identify risks and plant availability constraints?
How to validate the data for business decisions?
How to track variable costs by product, by area, by recipe?

Mining Mineral Processing Metallurgical Products

Energy Assets Reagents Environmental

Process Management Workflow

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Corporate Architecture with
Enterprise Center(s) of Compentency
Site Data Replication, Aggregation and/or
Consolidation and Access any where and
anytime SAP
Codelco Norte
Business
Systems

Firewall Other Sites, etc…

Microsoft
Portal
PI Servers
Server
Firewall

Client Apps PI PI Central

Server Server(s)
Teniente with HA
Client Apps

Firewall Engineering/R&D
PI
Server
Firewall More Client Apps

Client Apps PI
Server
Wireless
Mobile
Clients
Client Apps

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PI Fundamentals: The Shifting Platform Usage

Time Series
Data
Centric
Time Access

Series
Operations
Connectivity
Time Data
Centric Series
Context Access
Analytics
Context
(Data Directory)

Connectivity
Analytics

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Enterprise Agreement: Software
The Performance Inventory Asset Environmental Production Production
Applications KPI’s Visibility Management Reporting Planning Reporting
XCu Builds:

The Deliver Information

ReWebParts, for Meaningful,
Processbook, Datalink, SQC,
Visuals Betteradd-ins,
Batch Business Decisions
Manual Logger, etc..,

The Turn Valuable

Advanced Real-Time
Computing Engine, Data
PI
Analytics Notifications,
Into Actionableetc… Information

Historian, Analysis Framework, Module

The Gathers, Batch
Database, Organizes, Distributes,
management, Support of
Data and Stores
“High Data from Many Sources
Availability”

The Interfaces: Real-Time

Over 400 Standard
SCADA/
EquipmentPI ERP/
interfaces LAB Web
including IT Data
PLC/DCS Relational Data Data
Sensors/GIS
OLEDB and MCN Health Monitor

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Asset Grouping - Operation-Centric
Hierarchical

z Start with a collection of assets Connectivity

Equipment
z Associate data (tags) with the assets
z New assets are based on templates
z Assets can be connected Asset Attributes:
Name plate information
z Assets can be grouped Trays
Related data references
– By function Limits

– By location
z Calculations are sourced from assets
Mill 1
z Build once, apply to many Asset Attributes:
Name plate information
Related data references
z Visualize results from Operating limits

multiple assets with one graphic

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Copper Production Process

Major Energy Users

Rich Solution

Mine SX SX Electro
Crushing Agglomeration Leaching
Extraction Extraction Re-Extraction Winning

Organic Poor
Sulfuric Acid Loaded Electrolyte

Process Water Refine Solution

99.999% Cu

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Effect of Grade and Recovery on Energy
80% 70%
90% Recovery
100% Comminution Energy
30,000 72% of Milling Energy
kWh/T of Cu

20,000
Total Energy
Including Milling

10,000
Smelting
D.W. Fuerstenau, IMP Latam Rio J, 2001
Refining
0
0 0.5 1.0 1.5 2.5

z Mining
Ore Grade Milling
z Open Pit, hard rock 3-5 kWh/t ore < 100 mesh grind, flotation 15-24 kWh/t
z VALUE
Underground, NOW,
hard VALUE
rock OVER
12-40 TIME ore
kWh/t < 200 mesh grind, flotation
© 2008 OSIsoft, 24-34
Inc. | Company ConfidentialkWh/t9
Measurement Error

ε =ε +ε +ε
Total
Total Gross
Gross Bias
Bias Random
Random

z All measurement has error

z Meter Composite Accuracy

– Repeatability
– Accuracy
– Linearity

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Meter Composite Accuracy

Characteristic Meter Curve

Repeatability
Rate Error

Flow

Accuracy
Linearity

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Balancing Process

Manual Data
Process Data LIMS

PI Inventories

Analysis Model
Framework
Gross Error Check
Sigmafine
Reconciliation

Reconciled Data
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Verify meter performance
Meter 18 Meter 8
.00
750.00
-10.00
700.00
-20.00
650.00
-30.00
600.00
-40.00

-50.00 550.00

-60.00 500.00
-70.00
450.00
-80.00 y = 0.6773x + 121.01
y = 0.7732x - 13.639 400.00
-90.00 600.00 700.00 800.00
-100.00 meter18 Linear (meter18) .00 meter8 Linear (meter8)

Typical Meter Biased Meter

Meter 11
550.00

500.00

450.00

400.00

350.00

y = 1.3984x - 196.99 y = 0.9556x - 15.071

300.00
300.00 400.00 500.00 600.00
meter11 Linear (meter11) Linear (meter11)

“Sticky” Meter

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Mass and Energy Balance

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Water Balance

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Asset Management
z Common asset model
z Unrestricted access and
storage of high fidelity
data, including:
– Historical
– Real-time
– Future

VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 16
Example for Basic Industries
Business Perspective
P
R
1. What we do KPI’s (Management)
O
D
1. Variances (Plan – Current)
U 2. What we manage Metrics
C What we do
T 1. Production
S
2. Costs, KWh/ton, $/ton
M What we manage 3. Availability
A
N
4. Yields
U
F
5. Quality
6. Environmental
T 7. Safety
R
A 3. Plant Data
N
S Operations 1. Inventories
2. Lab
3. Process
R
4. Equipment
M
Process and People 5. Receiving/Shipping

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 Example PI - Minera El Tesoro

Modernización y Aumento de valor en las aplicaciones existentes

VERSION ACTUALPBOOK
VERSION 3.15
PBOOK 2.12

CONTEXT

General Structure for

each asset is
configured in Contex
Data Base

Module Relative
Display Example

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 Leaching Performance Monitoring
Modernización y Aumento de valor en las aplicaciones existentes

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Real Time Asset PI Notification and Analysis

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Office 2007 Excel Services with PI DataLink

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Enterprise Visibility
z Rich and easy to use
set of analytical tools
and capabilities,
including:
– Event detection and
notification built-in
– Configurable—no
programming required
– Scalability
Enterprise energy
Enterprise energy
management
management
infrastructure for
infrastructure for
managing energy
managing energy
price volatility
price volatility

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VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 23
KPIs
z Actual yields calculated via PI-ACE based on
reconciled values:
– Per hour
– Per shift
– Per running plan
z Overall KPIs calculated via PI-ACE
– Performance (positive when producing more valuable
products than expected)
– Deviation (gives indication of the distance between
target and actual yields)
z Show KPIs - change to notifications/AF

VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 24
Enterprise Water & Energy Management

Optimal
What Could be

t
m en
ve
ro
Design mp
Performance

I
o us What Should be
i nu
nt
Gap Co

What Is
Actual

Design System Continuous Monitoring, Analysis, and Action Time

commissioning

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VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 26
VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 27
Enterprise Center of Compentence

Virtual Site for access any where and anytime

BU 1
Business
Systems

Firewall BU 2
Portal
PI Servers
Server
Firewall

Client Apps PI
Server PI Central
Servers
BU 3
Client Apps

Firewall BU N
PI
Server
Firewall More Client Apps

Client Apps PI
Server
Wireless
Mobile
Clients
Client Apps
Mines, Concentrators, Smelters, Refineries, Power Plants, PI Servers (n)
4869 VALUE NOW, VALUE OVER TIME
© Copyright 03/2007 OSI Software GmbH - Company Confidential © 2008 OSIsoft, Inc. | Company Confidential 28
VALUE NOW, VALUE OVER TIME Centro de Monitoreo y Diagnóstico 29
© 2008 OSIsoft, Inc. | Company Confidential
VALUE NOW, VALUE OVER TIME Área de
© 2008Procesos yConfidential
OSIsoft, Inc. | Company Sistemas 30
 SALA DEL CMD

VALUE NOW, VALUE OVER TIME Centro de Monitoreo y Diagnóstico 31

© 2008 OSIsoft, Inc. | Company Confidential
OSIsoft’s Enterprise Agreement Program
• PI deployment across the defined enterprise
• Asset based licensing for unlimited use of core
OSIsoft After 25 years of designing,
PI products
• implementing
Simplified and supporting
contract & procurement processes
• Allowance for material OSIsoft
customers, change in business
realized
z customers
Automatic Download of needed a new
New Versions
z purchasing
Automated framework to
Upgrades Available
z Remote monitoring and alerting
z
encompass 3 components of
Help Desk, Developers Network and Training
software competency in a
z Managed rollout
single purchase plan
z Remotely PI management
z Center of Excellence (CoE) access
z Architectural design & application

OSIsoft’s Enterprise Agreement partnership program is designed to

maximize both Xstrata’s AND OSIsoft’s core competencies.

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Enteprise Sales Program
• PI deployment across the defined enterprise
• Asset based licensing
• Simplified contract & procurement processes
• Allowance for material change in business

z Automatic Download of New Versions

z Automated Upgrades Available
z Remote monitoring and alerting
z Help Desk, Developers Network and Training

z Managed rollout
z Remotely PI management
z Center of Excellence (CoE) access
z Architectural design & application

OSIsoft’s Enterprise Agreement Program is designed to “Get PI done right”

and ensure customers “Get value out of PI”

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The Enterprise Process

VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 34
Water and Energy Balances in Mineral
Processing Plants
Osvaldo Bascur and Ales Soudek

VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 35
Kodak Park

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Kodak Park Utilities

z Kodak Park Utilities Power Plants

– 2,000,000 Pound/Hour Steam Load
– 125 MW Electric Load
– 80,000 Ton Refrigeration Capacity
– 30,000,000 Gallons/Day Process
Water Load
– 35,000 SCFM Compressed Air Load

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VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 38
 Expanded use of our Energy Information
System has been an effective tool to help
enable us to consolidate two High Purity
Water Systems and a de-mineralized
water system down to just one High
Purity Water System.

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Harvest Time
z The Energy Information System (EIS)
has been an essential tool to help us
reach our goal of:
“One Powerhouse for Kodak Park”
Collectively these efforts have
yielded savings into the millions of
dollars.

VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 40
Lessons Learned

z No BIG BANG – 1000 little bangs

z Continuous Improvement Process
z Combined Capital and Intelligence Operation
z Infrastructure Approach – Remove Infrastructure
from Projects
z Lowers the Cost of Curiosity

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Metals Enterprise Business
z Objectives
– Site Integration for Enterprise Optimization
– Enterprise Competence Center
• Leverages expertise across entire enterprise
• Identify and promote best practices
• Tracks effectiveness of business processes
• Collaboration
z Required Tools and Supported Methodology
– Flexible Collection of Real-Time Data
– Asset-based Organization for Analysis
– Web-based, Easy Access to Information
– Scalable Analysis and Visualization
– Managed PI and COE Services

VALUE NOW, VALUE OVER TIME © 2008 OSIsoft, Inc. | Company Confidential 42