EXPO Salesiano 2010 - EO Miércoles II

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EXPO Salesiano 2010 - EO Miércoles II

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I.S.T. SILESIANOS

APLICACIÓN DE

TECNICAS AVANZADAS

EN EL ESTUDIOS DE

CONTROL DE LA

MOLIENDA DE BOLAS

EN YACIMIENTOS

MINEROS

FIEM – UTP

20 OCTUBRE 2010

OVERVIEW

MINERIA

EL CONTROL PREDICTIVO

CONCLUSIONES

LA MOLIENDA DE BOLAS Y SU IMPORTANCIA EN LA MINERIA

PROCESAR Y REFINAR LA GRANULARIDAD DEL MINERAL TRITURADO

DIMENSIÓN QUE DEBE SER ESTÁNDAR EN LOS PROCESADOS DE

MINERAL COMO LA FLOTACIÓN

TAMAÑO ÓPTIMO DEL GRANO MINERAL

CIRCUITO DE MOLIENDA EN UNA PLANTA

MINERA

OUTPUTS DE CUATRO

VARIABLES:

TAMAÑO DE LA

PARTICULA

SUMP LEVEL

CARGA CIRCULANTE

OUTPUTS DE CUATRO

VARIABLES:

TAMAÑO DE LA

PARTICULA

SUMP LEVEL

CARGA CIRCULANTE

Model Predictive Control

Objetivo: seguir la

trayectoria a través de un

setpoint

IMPLEMENTACION EN UNA PLANTA REAL QUE PROCESA COBRE

EN CHINA

CONCLUSIONES

ASENTAMIENTOS MINEROS

MINERAL PARA FACILITAR SU PROCESADO EN POSTERIORES ETAPAS

QUE CONTEMPLAN LA TRANSFORMADA DE LAPLACE

MODELING OF THE MINERAL PARTICLE-SIZE

EVOLUTION THROUGH STOCHASTIC INPUT

SIGNALS IN A BALLS MILL GRINDING CIRCUIT

JUAN TISZA-CONTRERAS

HUBER NIETO-CHAUPIS

UNIVERSIDAD NACIONAL DE

INGENIERÍA (UNI)

ded &

UNIVERSIDAD TECNOLÓGICA DEL

PERU (UTP)

ONFERENCE ANDESCON 2010 BO

this work.

Contribution to this investigation has been mainly

in the process control and engineering

considerations of the ball mill grinding circuit.

ded

Contribution to this investigation has been mainly

in the mathematical modeling

ONFERENCE ANDESCON 2010 BO

ded

on Engineering based at Lima and its major during last years has been

focused on branches of Electronics and Electrical Engineering. UNI has

played a notable role in preparing highest proffesionals in Perú.

10/21/10 UTP - UNI 15

ONFERENCE ANDESCON 2010 BO

ded

center of innovation and strong research in engineering and liberal arts. Is

well suited in local ranking and its intensive invest in R&D led to

10/21/10consolidate in a robust institution

UTP -by

UNIpromising tech and sciences to Perú.

16

ONFERENCE ANDESCON 2010 BO

OUTLINE

INTRODUCTION

DESCRIPTION THE PROCESS

DETERMINATION OF THE PROBLEM

ded PRESENTATION THE FORMALISM

RESULTS COMPARATIVE OF THE

SIMULATIONS

SUMMARY

ONFERENCE ANDESCON 2010 BO I. Introduction

the ade

activities as part of the development of a country

in several ways. Even though it is clear its

enormous impact on the economy and the

prospects of growing in future.

Recently, it has been paid attention

ded

on the so-called ball mill grinding circuits

because their role in the mineral plants. As

reported in the adequate functionality of a

grinding circuit might optimize the reduction

of unnecessary costs.

Most of the applied methodologies in the studies

of automation aimed to improve the functionality

of the circuit have used control schemes

10/21/10 UTP - UNI 18

ONFERENCE ANDESCON 2010 BO

such as those traditional techniques

like PID controllers.

In such studies a special attention has been

paid on the particle size variable due to the

fact that exist a direct relation between the

value of the particle size and the recovery of

minerals in final instances.

ded Recent studies have faced the problem of

identifying the whole system through multiple

inputs and multiple outputs since the

complexity of the system as manifested in the

evidence of the existence of several variables.

It actually constitutes one of the main

disadvantages of the ball mill grinding circuit

so that both nonlinearity and complex nature

should be taken into account its studies.

10/21/10 UTP - UNI 19

ONFERENCE ANDESCON 2010 BO An important point which has not been stress enough

at the past is related to the dynamic of the variables.

While the output variables have a clear dependence of

the input ones as described well by the relation with

the Laplace variable.. In this report, We preset a

mathematical model where we are contemplating

terms of interaction of variables in a ball mill grinding

circuit.

The fact that these terms could be the source of

spontaneous fluctuations is discussed.

ded

ONFERENCE ANDESCON 2010 BO

ORE MINERAL PROCESSING AT

CONCENTRATOR PLANT IN THE

ded MINING COMPANY

CRUSHING

GRINDING

FLOTATION

ONFERENCE ANDESCON 2010 BO

OVERVIEW OF THE PROCESS THE MINERAL

ded

ONFERENCE ANDESCON 2010 BO

ded

ONFERENCE ANDESCON 2010 BO III.- DETERMINATION OF THE PROBLEM

THE MORE IMPORTANT OUTPUT VARIABLE IN THE

GRINDING STAGE IS PARTICLE SIZE, THEREFORE THE

TESTING OF MODEL WE ARE PRESENTING IS GIVEN IN

RELATION WITH THIS VARIABLE, WHICH IS INFLUENCED

BY THE FRESH ORE FEED RATE, THE MILL FEED WATER

FLOW RATE AND DILUTION WATER, AS WELL AS THE

INTERACTIONS AMONG THEM DURING THE DYNAMICS OF

THE CIRCUIT.

ded FLUCTUATIONS ON THESE VARIABLES AND THEIR

ASSOCIATED INTERACTIONS MIGHT DEGRADE NOTABLY

THE PARTICLE SIZE. WE PRETEND FOCUS ON THE EFFECT

OF THE COUPLINGS OF VARIABLES FOR A SYSTEM

CONTAINING 3 INPUTS AND 3 OUTPUTS.

THEN IS INDICATED THAT INTERACTION COULD BE

DEFINED BY A STOCHASTIC FUNCTION SINCE NOT ANY

INFORMATION OF DETERMINISTIC NATURE IS KNOWN.

THUS, SIMULATIONS CORRESPONDING TO THIS CASE ARE

PERFORMED AND COMPARED TO THE CASE WHERE THE

SYSTEM IS FREE OF INTERACTIONS.

10/21/10 UTP - UNI 24

ONFERENCE ANDESCON 2010 BO

CONCEPTS ABOUT THE METHODOLOGY

MATHEMATICAL AND THE SIMULATIONS.

EVALUATED IN ORDER TO ASSESS THE PROSPECTS

BY USING THIS FORMALISM IN ORDER TO USE FOR

ded FURTHER CONTROL SYSTEMS.

ONFERENCE ANDESCON 2010 BO OVERVIEW OF THE PROBLEM

PROCESSING

ANALYSIS

EXPORTATION

ded ORE EXTRACTION

RECOVERY

TRADE-OFF

TREATMENT

ONFERENCE ANDESCON 2010 BO We focus on the problem of the

identification of the evolution of

the mineral particle-size after of

processing in a balls mill

grinding circuit.

WHY?

estimate of the modeling would

go a better control even in those

cases where several I/O are

involved.

ded

Min. Eng, 20, 1099–1108 (2007) this

research attemps to model the evolution of

the particle-size by including new concepts

based on stochastic formulations.

variables, it is almost impossible to assume

that the system would consist in a

dynamics fully deterministic. The presence

of many variables and their interactions

would insert some mechanisms purely

10/21/10 UTP - UNI 27

stochastic.

ONFERENCE ANDESCON 2010 BO DILEMMA: HAS OR DO NOT

In virtue of its complexity and operativity, a balls mill grinding circuit can be viewed under two

scenarios: one which contemplates no any interaction among the ones entering to the mill, and

the second one which contains interactions at least of one output and the corresponding inputs.

In this analysis, we shall go through the case where only one output do interact to the input ones.

contains interactions

ded

interactions

ONFERENCE ANDESCON 2010 BO THE SYSTEM AND DYNAMICS

INPUT OUTPUT

MINERAL ORE PARTICLE-SIZE

WATER SUMP LEVEL

DILUTION WATER CIRCULATING

LOAD

written as:

C ( s ) = G ( s ) G ( s ) G ( s ) R ( s )

C 21 22 23 A

S M ( s ) G31 ( s ) G32 ( s ) G33 ( s ) RD ( s )

10/21/10 UTP - UNI 29

ONFERENCE ANDESCON 2010 BO SYSTEM FUNCTIONALITY

The linearity of system is dictated by the transfer function which is

featured in having a well-defined delay. It is traduced in the functionality

of the circuit which runs in according to the feed of the mill.

e bs

G (s) = b = delay

(d + us ) d,u = systems’s constants

CIRCUL. PARTICLE

ded ORE WATER LOAD

SUMP INTERACTION

SIZE

It’s crucial for simulations ends: charge/hour, water flow, delays between

the pass of material (one-to-one), max. volumen in mill, diluted water

flow, full cycle time, water/ore rate in mill.

10/21/10 UTP - UNI 30

ONFERENCE ANDESCON 2010 BO

The variable of interest: the particle-size can be modeled at the s domain

by containing up to three input variables

In the time-domain, one can to write down the evolution through integral

equations:

t t

ded RP (t ) = ∫ g11 (ζ ) RM (t − ζ )dζ + ∫ g12 (ζ ) RA (t − ζ )dζ

0 0

t

+ ∫ g13 (ζ ) RD (t − ζ )dζ

0

The transfer functions are actually unknown and their description on the

time domain is better understood by means smooth polynomials:

10/21/10 UTP - UNI 31

ONFERENCE ANDESCON 2010 BO

It is usual to define the transfer function as a finite sum of the products

between the system coefficients and their respective polynomials

N (i , j )

g ij (ζ ) ≈ ∑ ij Φ q (ζ )

β q

q =1

This step led us to define a set of functions featuring the system and

depending upon the morphology of the polynomials

t

ded

Fijq (t ) = ∫ Φ q (ζ )RM (t − ζ )dζ

0

being lineal on the coefficients

RP (t ) = ∑ q Fq (t ) +

C

q

11 11

∑ q Fq (t ) +

C 12 12

q

∑ q Fq (t )

C

q

13 13

ONFERENCE ANDESCON 2010 BO

The manner as written before satisfies the fundamental relation only when

the system obeys a lineal regime

3 M (i , j ) 3

Yi (t ) = ∑ ∑ q q

C ij

X ij

(t ) ∝ ∑ C ij

X ij

(t )

j =1 q =1 j =1

Reflexions:

ded

- It’s actually the ball mills grinding circuit a linear system?

ONFERENCE ANDESCON 2010 BO

In fact, there is interaction for the case:

mill thereby interacting to the mineral ore

and/or water.

inputs” should be considered in a full

description of phenomenon.

ded

- We argue the following: if interactions

are applied to analysis, then all of them

should be of stochastic nature.

+ H12 ( s ) RA ( s ) H X ( s )CC ( s )

Interaction between the water and the circulating load

10/21/10 UTP - UNI 34

ONFERENCE ANDESCON 2010 BO

The full output is now written as a composition of two phenomena: one

being the simple case and the one which is subject to interactions

[ ]

∞

Yi (t ) ∝ C X (t ) + ∑ λC X (t )

n

ˆ ij ij ij ij

n

Coupling constant

ded

One can conclude that the interactions should be attained to nonlinear

terms to the full output. For the concrete case of the balls mill grinding

circuit:

[ ]

∞

Yˆi (t ) ∝ ∑ λC X (t ) → ij ij n

Stochastic

n

ONFERENCE ANDESCON 2010 BO COMPUTATIONAL SIMULATION

M (1,1) M (1, 2 )

RP (t ) = ∑ q Fq (t ) +

C

q

11 11

∑ q Fq (t )

C

q

12 12

M (1, 3)

+ ∑ q Fq (t )

C

q

13 13

ded

random variables and whose choice depends upon a Gaussian distribution

t −t 2

t2 − β − 2 1 − λ

~ ∆t

RP (t ) = RP (t ) + A0 ∫ e

dβ

1 t

10/21/10 UTP - UNI 36

ONFERENCE ANDESCON 2010 BO

INPUTS

CHOICE OF TO RECONFIGURATE

MINERAL WEIGHT NO

WATER FLOW T

MILL PROPERTIES

CHOICE OF RANDOM

CHOICE OF FUNCTIONS

FUNCTIONS For ΔT(i) > ΔT(i+i)

ded ARE CONVOLUTIONS

STABLE?

SET <C(i,j)>

PARAMETERS

STABILITY

AND FITTING

YES

CONVOLUCIÓN

PARTICLE-SIZE IS

ACCEPTED

ONFERENCE ANDESCON 2010 BO RESULTS OF SIMULATION

has been simulated under similar

conditions to the real ones.

The effect in inserting interactions

is manifested as a noise without

dramatical changes on the main

shape.

ded

STARTS THE CONTRIBUTION BY EFFECT OF INTERACTION

inputs were also tested. No

divergences were found, neither

strong fluctuations. So one can

state that the inclusion of

interactions in the modelling

would be the most realistic way to

be implemented in control

systems.

10/21/10 UTP - UNI 38

ONFERENCE ANDESCON 2010 BO CONCLUSIONS

IT IS A FIRST ATTEMP TO MODEL THE PARTICLE-SIZE

UNDER QUASI-REAL CONDITIONS: THE IMPLEMENTATION OF

INTERACTIONS

THE SHAPE OF THE PARTICLE-SIZE EVOLUTION GETS SOFT

FLUCTUATIONS JUST ON THE RANGE WHERE THE

CIRCULATING LOAD APPEARS TO BE NOT NEGLIGIBLE.

MIGHT BE AN EFFICIENT INGREDIENT TO CARRY OUT WELL

ACCURATE CONTROL SYSTEMS.

PROBLEM OF MODELLING THE BALLS MILL GRINDING

CIRCUIT INSIDE A MIMO CONTEXT AND NONLINEARITIES.

ISSUE OF TWO OUTPUT VARIABLES: PARTICLE-SIZE AND

SUMP LEVEL.

10/21/10 UTP - UNI 39

ONFERENCE ANDESCON 2010 BO

ded

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