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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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slide1

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

slide2

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

slide3

MPOS - Operator Training - Control Room Displays

MPOS CIMExcel Software Inc. Slide 3

slide4

MPOS - Operator Training - Popup Controls

MPOS CIMExcel Software Inc. Slide 4

slide5

MPOS - Controls and Trends Display

MPOS CIMExcel Software Inc. Slide 5

slide6

MPOS - Additional Displays

MPOS CIMExcel Software Inc. Slide 6

slide7

MPOS - Training Scenarios

MPOS CIMExcel Software Inc. Slide 7

slide8

MPOS - Completely Configurable

MPOS CIMExcel Software Inc. Slide 8

slide9

MPOS - Semi-Autogenous Mill Model

MPOS CIMExcel Software Inc. Slide 9

slide10

MPOS - Autogenous Mill Model

MPOS CIMExcel Software Inc. Slide 10

slide11

MPOS - Pebble Crusher Model

MPOS CIMExcel Software Inc. Slide 11

slide12

MPOS - Ball Mill Model

MPOS CIMExcel Software Inc. Slide 12

slide13

MPOS - Cyclone Model

MPOS CIMExcel Software Inc. Slide 13

slide14

MPOS - Flotation Model

MPOS CIMExcel Software Inc. Slide 14

slide15

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

slide16

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

slide17

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

slide18

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

slide19

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

slide20

Stockpile - Feeders Model

MPOSCIMExcel Software Inc. Slide 20

slide21

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

slide22

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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