Mineral Processing Operations Simulator (MPOS)
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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.

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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 1


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

  • CIMExcel Software Inc. Slide 2


    • MPOS - Operator Training - Control Room Displays

    MPOS CIMExcel Software Inc. Slide 3


    • MPOS - Operator Training - Popup Controls

    MPOS CIMExcel Software Inc. Slide 4


    • MPOS - Controls and Trends Display

    MPOS CIMExcel Software Inc. Slide 5


    • MPOS - Additional Displays

    MPOS CIMExcel Software Inc. Slide 6


    • MPOS - Training Scenarios

    MPOS CIMExcel Software Inc. Slide 7


    • MPOS - Completely Configurable

    MPOS CIMExcel Software Inc. Slide 8


    • MPOS - Semi-Autogenous Mill Model

    MPOS CIMExcel Software Inc. Slide 9


    • MPOS - Autogenous Mill Model

    MPOS CIMExcel Software Inc. Slide 10


    • MPOS - Pebble Crusher Model

    MPOS CIMExcel Software Inc. Slide 11


    • MPOS - Ball Mill Model

    MPOS CIMExcel Software Inc. Slide 12


    • MPOS - Cyclone Model

    MPOS CIMExcel Software Inc. Slide 13


    • MPOS - Flotation Model

    MPOS CIMExcel Software Inc. Slide 14


    • Flotation Cell Level Dynamics

    Qair 1

    L1

    Qair i

    ρ1

    U1

    Li

    Qair n

    Qin

    V1

    ρi

    Sin

    Ui

    z1

    Ln

    Vi

    ρn

    Un

    zi

    Vn

    • note,

    • Vi = valve position

    • Ui = valve positioner

    MPOSCIMExcel Software Inc. Slide 15


    Flotation Cell Level Dynamics

    • d/dt V1 = A1 d/dt L1 = d/dt Va1 + d/dt Vp1

    • A1 d/dt L1 = d/dt Va1 + Qin - Q1out

    • = d/dt Va1 + Qin - α1 f1(V1)(ρ1L1 + ρ1z1 - ρ2L2 )0.5

    • Ai d/dt Li = d/dt Vai + Qi-1out - Qiout

    • = d/dt Vai + αi-1 fi-1(Vi-1)(ρi-1Li-1 + ρi-1zi-1 - ρiLi )0.5 - αi fi(Vi)(ρiLi + ρizi - ρi+1Li+1 )0.5

    • An d/dt Ln = d/dt Van + Qn-1out - Qnout

    • = d/dt Van + αn-1 fn-1(Vn-1)(ρn-1Ln-1 + ρn-1zn-1 - ρnLn )0.5 - αn fn(Vn)(ρnLn )0.5

    • α1 , αi , αn constants.

    • L1 , Li , Ln from bottom of tank.

    • z1 = tank 1 – tank 2 elevations. zi = tank i - tank i+1 elevations. zn = 0.

    • Q1out = Qin + d/dt Va1 - A1 d/dt L1

    • = α1 f1(V1)(ρ1L1 + ρ1z1 - ρ2L2 )0.5

    • Q2out = Q1out + d/dt Va2 - A2 d/dt L2 = Qin + d/dt Va1 + d/dt Va2 - A1 d/dt L1 - A2 d/dt L2

    • Qiout = Qin + ∑j=1i (d/dt Vaj - Aj d/dt Lj)

    • = αi fi(Vi)(ρiLi + ρizi - ρi+1Li+1 )0.5

    • Qnout = Qin + ∑j=1n (d/dt Vaj - Aj d/dt Lj)

    • = αn fn(Vn)(ρnLn )0.5

    MPOSCIMExcel Software Inc. Slide 16


    Flotation Cell Level Dynamics

    • solids:

    • τs1 d/dt S1 = Sin - S1

    • τsi d/dt Si = Si-1 - Si

    • τsn d/dt Sn = Sn-1 - Sn

    • solids time constant:

    • τs1 = ρ1 V1 / ρin Qin

    • τsi = ρi Vi / ρs i-1 Qi-1

    • τsn = ρn Vn / ρs n-1 Qn-1

    • slurry density from solids:

    • ρs1 = ρore/ ( S1 + (ρore/ρwater)(1 - S1) )

    • Ρs i = ρore/ ( Si + (ρore/ρwater)(1 - Si) )

    • ρsn = ρore/ ( Sn + (ρore/ρwater)(1 - Sn) )

    • cell density:

    • ρ1 = ρs1(1 - f1 )

    • ρi = ρsi(1 - fi )

    • ρn = ρsn(1 - fn )

    MPOSCIMExcel Software Inc. Slide 17


    Flotation Cell Level Dynamics

    • cell air:

    • f = void fraction

    • τar i = cell average rise time (s)

    • affi = cell averaged void fraction - air flow factor

    • 0.5τar 1 d/dt f1 = aff1 Qain1 - f1

    • 0.5τar i d/dt fi = affi Qain i - fi

    • 0.5τar n d/dt fn = affn Qain n - fn

    • Vai = Vi fi= Ai Li fi

    • d/dt Va1 = 2A1 L1 (aff1Qain1 - f1) / τar 1

    • d/dt Vai = 2Ai Li (affiQaini - fi) / τar i

    • d/dt Van = 2An Ln (affnQainn - fn) / τar n

    MPOSCIMExcel Software Inc. Slide 18


    • Flotation Cell Level Dynamics

    • open loop response

    Cyclones 5 -> 6 -> 4 -> 5, Air Flow - Flow Ratio Control, Solids Setpoint Control @ 50%

    MPOSCIMExcel Software Inc. Slide 19


    • Stockpile - Feeders Model

    MPOSCIMExcel Software Inc. Slide 20


    • MPOS - Process Units

    • Primary and Secondary Crushers

    • Stockpile Ore Quality Distribution

    • Apron and Pan Feeders

    • Ore Conveyors

    • SAG / AG Mills - Wear, Steel, Ore, Water, Speed, Power, Load, DE Particle Size

    • Screen Feed Pump Box - Level and Solids

    • Screening - Particle Size Distribution

    • Grinding Mills - Lube Oil Systems

    • Pebble Crusher - Particle Size Distribution

    • Ball / Rod Mill - Solids, Power, DE Particle Size

    • Cyclone Feed Pump Box - Level and Solids

    • Cyclones - Mass Flows, Solids, Particle Size, and Partition

    • Cyclone Sets - Pressure, Solids and Flow

    • Flotation - FE Particle Size, Solids and Flow

    • Flotation - Air and Reagents Addition

    • Flotation - Metal Recovery

    • Tailings - Particle Size, Solids, Flow, and Sanding

    MPOS CIMExcel Software Inc. Slide 21


    • MPOS - Conventional and Advanced Control Loops

    • Lube Oil Systems

    • Apron and Pan Feeder Speed

    • SAG / AG Mill - Feedrate

    • SAG / AG Mill - Power and Load

    • SAG / AG Mill - Water Ratio

    • SAG / AG Mill - Speed

    • SAG / AG Mill - Water Addition

    • Screen Feed Pump Box Level

    • Pebble Crusher

    • Cyclone Feed Pump Box Level

    • Cyclone Scheduling

    • Cyclone Underflow Water Addition

    • Cyclone Overflow Water Addition

    • Cyclone Overflow Solids

    • Flotation Air and Reagents

    MPOS CIMExcel Software Inc. Slide 22


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