MODEL PREDICTIVE CONTROL APPLICATION AT LUMWANA COPPER CONCENTRATOR
|
|
- Donald Houston
- 5 years ago
- Views:
Transcription
1 MODEL PREDICTIVE CONTROL APPLICATION AT LUMWANA COPPER CONCENTRATOR Mick Rogers Process Manager, Lumwana Mining Company, Zambia David G Almond Global Product Manager Minerals Process Control, FLSmidth Inc., Automation Division, USA Tejas D. Maru Development Engineer, FLSmidth Inc., Automation Division, USA King Becerra Product Manager, High Level Process Control, FLSmidth Inc., Automation Division, USA ABSTRACT Equinox Minerals has constructed and is operating a new mine; Lumwana Mining Company located close to Solwezi in the North Western province of the Republic of Zambia. The plant employs a conventional copper processing circuit whereby low grade, primary crushed copper ore is processed through a SAG/Ball mill circuit and flotation to produce concentrate. Plant nameplate design capacity is 20 million dry metric tons per annum. To optimize the operation and ramp up production, Lumwana Mining Company signed a contract with FLSmidth Automation to implement FLSmidth s advanced process control solution, the ECS/ProcessExpert System. This paper presents the implementation results and performance data recorded during system evaluation. The results conclusively demonstrate benefits during circuit operation with the system ON. INTRODUCTION The Lumwana processing plant grinding circuit is of conventional design, consisting of a SAG/Ball milling circuit closed by cyclones. Powered by Siemens Gearless Mill Drives, the mills were supplied by FLSmidth and cyclones and cyclone feed pumps by FLSmidth Krebs. Low grade copper ore from the primary crushed ore stockpile is reclaimed via two variable speed apron feeders onto the primary mill feed belt. Primary grinding is achieved in an 18MW, 11.58m diameter x 5.49m EGL SAG mill discharging over a steel trommel into a sump shared with the secondary ball mill. Trommel oversize is recycled back to the SAG mill feed chute via two conveyors. Primary ground slurry is pumped by twin variable speed MF600 MillMax pumps to twin cyclone packs of eight
2 838mm GMax cyclones each. Cyclone underflow gravitates to the 16MW, 7.92m diameter x 12.19m EGL secondary ball mill discharging into the common sump. Cyclone overflow flows to the flotation circuit. The circuit described together with available measurements and actuators is shown in Figure 1 below. Figure 1: Lumwana circuit flow sheet Large mineral deposits such as that processed at Lumwana Mining Company (LMC), typically comprise ore of significantly varying characteristics and these create feed conditions that make stable operation of the circuit challenging. Furthermore, the mine development program has resulted in a significant period of tonnage ramp up and occasions when it has been necessary to operate the plant in a significantly turned down condition. To facilitate ramp up to full production LMC decided to install an advanced process control (APC) system. Since FLSmidth was the supplier of the grinding circuit equipment they were selected to supply the APC. ECS/ProcessExpert The system implemented was developed based on FLSmidth s ECS/ProcessExpert System (PxP), an advanced process control solution used to stabilize and then optimize key plant processes. The system was supplied as a complete solution for custom modeling and control application. For this application, advanced techniques (model predictive control and fuzzy-logic) were used in the application modules to enable hybrid control schemes that meet the specific process control requirements. These modules perform complex and continuous evaluations of process
3 conditions and execute control actions on a more frequent and reliable basis than human operators. Being an open toolbox, PxP allows the solution to be specifically tailored to the needs of the plant by incorporating the best control knowledge. Application objectives The objectives of the PxP grinding circuit application are: Stabilize SAG mill operation and prevent over filling of the SAG mill. Minimize circuit stoppages and allow controlled operation at maximum and significantly reduced feed rates. Optimize control and balance loads between the SAG and ball mills. Protect the SAG mill against undesirable liner impacts (monitored by a specialized instrument called an Impactmeter). Avoid sump spillage and maintain cyclone inlet pressure to set points. Maintain constant flow to the flotation plant. Keep particle size analysis (manual value) on target. Improve grind and energy efficiency. The PxP graphical operator interfaces for the primary and secondary grinding circuits are shown in Figures 2 and 3 below. Both user interfaces display the controller mode, control status (indices), online measurements, actuators, main mimic and a trend display. The user interface was designed to easily identify the actions being performed by the controller and enable the operator to partially enable/disable the control strategy whenever an instrumentation or process problem occurs. Information regarding the utilization of the system is also displayed. Figure 2: ECS/ProcessExpert operator station graphical interface primary grinding circuit
4 Figure 3: ECS/ProcessExpert operator station graphical interface secondary grinding circuit METHODOLOGY An eight-step methodology was followed to assure the success of the ECS/ProcessExpert Grinding Circuit application. This methodology comprises all the activities and steps that are required for an efficient development of advanced process control solution, aligning customer expectations with the application goals for the successful commissioning of the system. In summary, the eight-step methodology comprises the following activities: 1. Project planning 2. Kick-off and process interviews 3. Application Design 4. Primary commissioning 5. ECS/ProcessExpert training 6. Remote monitoring and tuning 7. Follow-up visit 8. Long-term support To evaluate the project success a test protocol defining the main guidelines to measure operational benefits was agreed between LMC and the supplier. The process control techniques, implementation timeframe, control strategy and results are presented below. Techniques The advanced process control solution was developed based on FLSmidth s ECS/ProcessExpert System. At this application has sparse number of measurements and actuators and involve a
5 multi-time scale delayed process, model predictive control (MPC) was identified as the best technique for this application complemented by fuzzy logic rules. The model predictive control technology uses a mathematical model of the process to predict future process behavior and pre-plan actions in the future to attain desired targets. The controller output is a manipulated variable (MV) applied to the inputs of the process and the process model, and is a part of every MPC controller. The process model computes a predicted trajectory of the controlled variable (CV) that is the process output. After correction of this trajectory for any mismatch between the predicted value and an actual measured value of the controlled variable, the predicted trajectory is subtracted from the future trajectory of the set point to form an error vector (Figure 4) [1]. CV Setpoint trajectory Predicted errors CV prediction MV Future calculated moves Past Future time Figure 4: Graphic illustration of the operation of a MPC controller System implementation The system was prepared at the suppliers premises and installed at the plant in August Establishing communications with the main process control system was a simple matter due to the compatible drivers installed in the PxP. Checking of signals and tags was completed within 5 working days thereafter the system was left gathering data and under remote monitoring from the USA for a period of 12 weeks. Commissioning of the system was complete after a further 6 weeks on site permitted control strategies and setup to be incorporated into the ECS/ProcessExpert. Final tuning of the system was completed via a remote connection using the connection established during installation by the supplier. General control strategy As part of the application design, the key process measurements required for control were identified between LMC and FLSmidth. It was decided to split the application into two main modules or components; the primary grinding circuit comprising the SAG Mill and raw ore feed and the secondary grinding circuit comprising the ball mill, sump and cyclones. The SAG mill control strategy was developed with the following main goals in mind: SAG mill load stability SAG mill throughput optimization
6 Reduction of charge generated undesirable impacts The above goals were attained through maintaining SAG mill load to set points; the SAG mill load is measured using the bearing pressure and controlled by speed and feed together with signals from an FLSmidth Impactmeter. The primary control technique used in the structure of expert system is MPC based. Combination of Fuzzy Logic and MPC is used in the construction of the SAG mill centrifuge identifier and SAG mill weight optimizer. The expert System has an option to use the MPC based on transfer function as well as state space. The MPC technique used in this application is based on transfer function. Table 1 illustrates the process measurements used as inputs and the outputs of the MPC controller. Table 1: Inputs and outputs of the MPC MPC Inputs SAG Mill Power SAG Mill Weight SAG Mill Solid % (SAG Density) Critical Impacts Cyclone Inlet Pressure Cyclone Flow Sump Level Ball Mill Bearing Pressure MPC Outputs SAG Mill Feed SAG Mill Speed SAG Mill Water Flow Sump Water Flow Cyclone Pump Speed Ball Mill Water Flow The process models were obtained to understand the effects of actuators and disturbances on the process measurement. The majority of the models were developed from plant data based on the response of the process measurements by manipulating the actuators. Some of the models were also obtained from the design data of the equipment and then were compared with the real time models obtained from plant data to compare the quality of models. Figure 5 illustrates the three different modes to control the SAG mill with the ECS/ProcessExpert System: startup control mode, normal control mode and upset control mode. Upset Control Mode Normal Control Mode Startup Control Mode Figure 5: ECS/ProcessExpert control modes
7 The SAG mill upset control mode is designed to handle unexpected and sudden disturbances to the SAG mill. This upset control mode will bring the process back to normal operation as soon as the process disturbances disappear. Inclusion of impact monitoring via signals from the Impactmeter have also been built into the load control strategy and monitors and prevents the mill from being run at excessive speed while maintaining the load to ensure good ore reduction, but avoiding critical impacts to protect the mill liners. A SAG mill weight target optimizer was developed to automatically establish the SAG mill weight target, manage mill critical impacts and adjust the SAG mill load according to the ore condition. This function optimizes the SAG mill weight target by correlation of the historic data of mill weight, current mill weight target, mill critical impacts and mill speed whenever the SAG mill experiences critical impacts during normal operation. Within the secondary grinding circuit the mills'discharge sump level control and cyclone classification control strategies were also implemented using model predictive control techniques. Stability of operation of the downstream flotation circuit is essential to maximising recovery, thus an important criteria for the PxP was to reduce fluctuations in flow and grinding circuit product size. Stable flow and constant size distribution is dependent on good cyclone operation which requires stable cyclone pressure and density control as well as smooth change over when the number of cyclones operating in each of the two cyclone banks is varied. The absence of density meters prevented density control by the PxP so focus was on maintaining constant pressure and flows through management of pumps speed and cyclones selection. RESULTS AND DISCUSSIONS A test protocol to assess potential operational and economic benefits resulting from the implementation of the PxP was agreed between LMC and FLSmidth. The test period was defined to run for 2 weeks and included the main variables which influence operational and economical benefits: tonnes per hour (tph), specific power (kwh/t), cyclone inlet pressure (kpa), SAG mill weight (t) and particle size analysis (in microns). The test protocol definition included running the mill for 15 hours (single period) with the PxP ON and OFF in a randomized sequence. The test protocol was executed during February 2010 and eight periods were identified as valid for analysis and measurement of operational benefits (four periods with the PxP ON and four with it OFF). After gathering and comparing results, main achievements of the implementation of the PxP on the Grinding Circuit of LMC are: Circuit stability on startup was attained twice as quickly with the PxP ON as than when it was OFF (within 60 minutes). Reduction of 3.4% in cyclone feed pump energy consumption. Reduction of 64% in SAG mill weight variability. Reduction of 14% in mill undesirable critical impacts occurrences. Although the impact meter is used to prevent critical impacts during ON and OFF test, the PxP was more efficient at reducing undesirable critical impacts. Through improved stability and control of the pumps and cyclone pressures, cyclone operation within the optimum pressure range specified by the supplier was achieved for
8 twice as much operational time with the PxP ON than with it OFF, keeping product grind on target. Pump 1 speed: 42% process variability reduction. Pump 2 speed: 44% process variability reduction. Cyclopack 1 Pressure: 54% process variability reduction. Cyclopack 2 Pressure: 65% process variability reduction. Better representation of the stability results are illustrated in Figures 6 and 7. Figure 6 illustrates the SAG mill weight standard deviation for each period with and without the PxP and reflects how the SAG mill weight process variability was reduced in average 64%, while maintaining the required target. Mill Weight Standard Deviaton Standard Deviation st period 2nd period 3rd period 4th period Period PXP ON PXP OFF Figure 6: Mill weight standard deviation by period Figure 7 illustrates the improved stability in cyclones pressure control. Cyclones operation within the optimum pressure was maintained for twice as much operational time with the PxP ON than with it OFF. CycloPack Pressures 70% 60% 50% 56.7% % Time 40% 30% 20% 10% 0% 33.5% 28.8% 21.8% 15.7% 13.6% 13.3% 8.1% 8.4% 0.1% > <80 KPa PXP ON PXP OFF Figure 7: Percentage of time cyclopack pressures was within each operational range
9 Improvements in consistency and stability of grinding circuit control is expected to yield benefit in terms of ultimate circuit capacity and overall circuit power efficiency when the PxP system is allowed to run "open" without ore supply constraint. Similarly, the improvement in stability of the grinding circuit in terms of product quality and flow rate output translates directly to improved stability in the flotation circuit, which is expected to result in some improvement in recovery of copper. The reduction in pump speed variation resulted in an increase in pump power efficiency, which coupled with the expected concomitant wet end wear reduction translates to significant financial benefit. Additionally, improvement in pressure and flow control is expected to yield wear benefit beyond that associated with higher power efficiency. Fluctuating pump speed generates pressure surges in the pump casing which can force slurry down the front and back of the impeller running clearances. This will accelerate wear on the suction liner and wear ring due to an increase in solids being dewatered by the higher pressure as it passes through the wear ring clearance. Pressure surges at the back impeller clearance can also exceed the inlet gland water pressure and result in spurts of slurry exiting the gland. The solids in the slurry can impregnate the soft gland packing and result in wearing the shaft sleeve which could result in the pump having to be stripped for overhaul prematurely. An accelerated flow in the pump will increase wear at the eye of the impeller and at the pump casing cutwater. CONCLUSIONS The ECS/ProcessExpert System has been successfully implemented on the grinding circuit at Lumwana Mining Company. The recorded results demonstrate benefits during circuit operation with the PxP ON. Circuit stability and improved equipment performance were significantly better than during manual control. An ECS/ProcessExpert model predictive control module has been used as the main process control technique, surpassing limitations of traditional control techniques, such as PIDs. The model predictive control technology has proven its ability to effectively control the grinding circuit. At the time of preparing this paper the system utilization was 98%. System utilization is an indirect measure of success of advanced process control projects. This utilization is very high and is attributed to the robust nature of the installed system platform together with a high degree of operator confidence. The test protocol was executed as a randomised block trial under similar process and operational conditions to assure the representativeness of data. While issues with availability of ore supply to the grinding circuit and plant reliability limited the number of valid data points obtained during the trial period, the PxP system demonstrated the ability to improve performance of the Lumwana grinding circuit. In summary, pump power and wear savings were demonstrated, circuit stability on startup was attained twice as quickly, cyclone feed flow variation was significantly reduced and cyclones were operated within the optimum pressure range for twice more operational time with the PxP ON than with it OFF. Although not tested, it is expected that increased average ultimate grinding circuit capacity will result from the improved stability of operation with PxP ON, as well as improved recovery due to reduction of frequency and magnitude of surging in the flotation circuit.
10 To assure longevity of the system and continued efficiency, remote monitoring services for troubleshooting and tuning are available through a secure internet connection which enables the supplier s technical experts to effectively support the system remotely. Despite this, the system has proved itself to be extremely reliable and no additional tuning has been necessary since it was handed over to the plant. ACKNOWLEDGEMENTS The authors acknowledge and thank the following: The management and staff of Lumwana Mining Company for their support in gathering and analyzing evaluation data and for approval to present these results. Pat Turner and John Frater of FLSmidth Krebs for assistance provided in analyzing cyclone and cyclone feed pump performance. The management of FLSmidth for approval to present performance evaluation of the ECS/ProcessExpert System. NOMENCLATURE SAG Semi-Autogenous Grinding LMC Lumwana Mining Company APC Advanced Process Control ECS Expert Control & Supervisory PxP ECS/ProcessExpert System EGL Effective Grinding Length MPC Model predictive Control MV Manipulated Variable CV Controlled variable PSM Particle Size Measurement REFERENCES Blevins, T.L, McMillan, G.K., Wojsznis, W.K. & Brown. M.W (2003) Advanced Control Unleashed. ISA-The Instrumentation, Systems, and Automation Society, pp. 309 [1]
MODEL PREDICTIVE CONTROL TO OPTIMIZE MILLING CIRCUITS USING NKOMATI NICKEL MINE AS A CASE STUDY
MODEL PREDICTIVE CONTROL TO OPTIMIZE MILLING CIRCUITS USING NKOMATI NICKEL MINE AS A CASE STUDY King Becerra Product Manager, Advanced Process Control (FLSmidth Inc.) ABSTRACT This paper reviews the installation
More informationIncreasing Grinding Circuit Robustness with Advanced Process Control
Increasing Grinding Circuit Robustness with Advanced Process Control A.Rantala, P.Blanz, K.Aberkrom, O.Haavisto MetPlant 2015, 7-8 September, Perth Outline Introduction Basic control of grinding Key measurements
More informationMILLING CONTROL & OPTIMISATION
MILLING CONTROL & OPTIMISATION MillSTAR OVERVIEW Due to the complex nature of milling circuits, it is often found that conventional control does not address many of the common problems experienced. These
More informationSAG Page 2. Page 1
Page 1 SAG 2 0 0 6 DEPARTMENT OF MINING ENGINEERING UNIVERSITY OF BRITISH COLUMBIA Vancouver, B. C., Canada CURRENT TRENDS IN SAG AND AG MILL OPERABILITY AND CONTROL By John Karageorgos 1, Paul Genovese
More informationFLOTATION CONTROL & OPTIMISATION
FLOTATION CONTROL & OPTIMISATION A global leader in mineral and metallurgical innovation FLOATSTAR OVERVIEW Flotation is a complex process that is affected by a multitude of factors. These factors may
More informationA Holistic Approach to Control and Optimisation of an Industrial Crushing Circuit
A Holistic Approach to Control and Optimisation of an Industrial Crushing Circuit D Muller*, P.G.R de Villiers**, G Humphries*** *Senior Process Control Engineer, Anglo Platinum, Control and Instrumentation
More informationOperational Excellence on the plant floor and in the control room: A disciplined approach to understanding the opportunities to maximise the
Operational Excellence on the plant floor and in the control room: A disciplined approach to understanding the opportunities to maximise the performance of your assets through the use of instrumentation
More informationSAGwise total process control The key to efficient SAG mill operation
SAGwise total process control The key to efficient SAG mill operation WE DISCOVER POTENTIAL Maximising your SAG mill s performance Low-grade, complex mineral deposits call for intelligent and efficient
More informationHigh pressure grinding rolls applications for the platinum industry
KNECHT, J. and PATZELT, N. High pressure grinding rolls applications for the platinum industry. International Platinum Conference Platinum Adding Value, The South African Institute of Mining and Metallurgy,
More information20 June Pat Turner, President FLSmidth Krebs. Pumps and Cyclones. Capital Market Day 2017
20 June 2017 Pat Turner, President FLSmidth Krebs Pumps and Cyclones Pumps and Cyclones in a nutshell World leader in cyclones, strong player in slurry pumps Critical equipment for productivity in minerals
More informationSAGDesign TM Using Open Technology for Mill Design and Performance Assessments
SAGDesign TM Using Open Technology for Mill Design and Performance Assessments John Starkey and Kingsley Larbi Starkey & Associates Inc., Oakville, Ontario, Canada ABSTRACT The advent of direct measurement
More informationSAG Page 1. Page 2
Page 1 Page 2 SAG 2 0 0 6 DEPARTMENT OF MINING ENGINEERING UNIVERSITY OF BRITISH COLUMBIA Vancouver, B. C., Canada grade Cannington resource is classified at 42 million tonnes, 551ppm silver, 12.1% lead
More informationThe implications of ore hardness variability on comminution circuit energy efficiency (and some other thoughts)
The implications of ore hardness variability on comminution circuit energy efficiency (and some other thoughts) Peter Amelunxen Thursday 6 December 2012 Capital (Millions) Current Cu/Mo Mill Design (a
More informationAPPLICATION AND BENEFITS OF ADVANCED CONTROL TO ALUMINA REFINING
Light Metals 2004 (The Minerals, Metals & Materials Society), 2004 APPLICATION AND BENEFITS OF ADVANCED CONTROL TO ALUMINA REFINING Robert K. Jonas Honeywell Int., 2500 W. Union Hills Dr., Phoenix, AZ,
More informationFEATURES AND BENEFITS
SGS MINERALS SERVICES T3 SGS 1079 MET PLATFORM SGS Minerals Services is the industry leader in providing support and creating solutions for mining projects worldwide. SGS offers advanced process control
More informationIncreasing Productivity Without Capital Expenditure
Increasing Productivity Without Capital Expenditure Grinding Circuit Advanced Control Provides Quick Payback at Gold Mine Operations Abstract 3.8 kilometres long, 1.35km wide and going down more than 500m,
More informationProcess optimization using real time tracking of coarse material in individual cyclone overflow streams
Process optimization using real time tracking of coarse material in individual cyclone overflow streams Dylan Cirulis 1, Scott Dunford 2, Jennifer Snyder 3, Erik Bartsch 4, Paul Rothman 5, Robert Maron
More informationGoulds XHD. Lenntech. Extra Heavy Duty World-Class Lined Slurry Pumps. Tel Fax.
Goulds XHD Extra Heavy Duty World-Class Lined Slurry Pumps Lenntech info@lenntech.com Tel. +31-152-610-900 www.lenntech.com Fax. +31-152-616-289 Goulds XHD Proven leadership in mining and mineral processing
More informationDevelopment and Implementation of the new 2240 kw (3000 HP) VERTIMILL Grinding Mill for Newcrest
Development and Implementation of the new 2240 kw (3000 HP) VERTIMILL Grinding Mill for Newcrest Cadia Valley Operations Jonathan Allen and Brian Knorr Presenter: Raul Noriega Previous Scale Up Previous
More informationJME Journal of Mining & Environment, Vol.2, No.1, 2011,
JME Journal of Mining & Environment, Vol.2, No.1, 2011, 27-40. Application of SPI for Modeling energy consumption in Sarcheshmeh SAG and ball mills M. Jahani 1, M. Noaparast 2*, A. Farzanegan 3, G. Langarizadeh
More informationAbstract. 1 Introduction. Golder Associates Ltd, Canada
https://papers.acg.uwa.edu.au/p/1752_05_gu/ Challenges associated with the design of a dewatering plant that will undergo a large increase in tailings throughput during the initial years of the project
More informationCrushing. Comminution
Comminution In order to separate the minerals from gangue (the waste minerals), it is necessary to crush and grind the rock to unlock, or liberate, valuable minerals so that they are partially or fully
More informationKnowledgeScape! EfficiencyExpert! Increase Profit. Reduce loss.
KnowledgeScape EfficiencyExpert Increase Profit. Reduce loss. EfficiencyExpert is the ultimate in comprehensive minerals processing solutions combining all of our strategies and Smart Sensors in a single
More informationMinerals. WARMAN Centrifugal Slurry Pumps WBV Vertical Cantilever Slurry Sump Pump Series
Minerals WARMAN Centrifugal Slurry Pumps WBV Vertical Cantilever Slurry Sump Pump Series The Warman WBV ultra heavy-duty range of vertical cantilevered slurry pumps sets a new industry benchmark for general
More informationNew project in Russia with semiautogenous mill selected according to the results of SAGDesign testing
New project in Russia with semiautogenous mill selected according to the results of SAGDesign testing ABSTRACT 507 Yury V. Kulikov, Arkady Y. Senchenko* John Starkey TOMS institute, Ltd., Russia TOMS institute,
More informationSAG Mill Control at Northparkes Mines (Not So Hard After All)
Mines (Not So Hard After All) A. J. Thornton, Principal Process Control Engineer 1 Tom Pethybridge, Production Superintendent OPD 2 Tom Rivett, Process Control Engineer 2 Richard Dunn, Metallurgical Superintendent
More informationADVANCED PROCESS CONTROL FOR YARA UREUM PLANT BRUNSBÜTTEL
ADVANCED PROCESS CONTROL FOR YARA UREUM PLANT BRUNSBÜTTEL SVEN KOHNKE, YARA BRUNSBÜTTEL, GERMANY BRAM LEEN, IPCOS, BELGIUM TOM BOELEN, IPCOS, BELGIUM CHRISTIAAN MOONS, IPCOS, BELGIUM 1 Abstract IPCOS,
More informationSukari revise Gold production in Egypt
Sukari revise Gold production in Egypt 1 2 Sukari Gold mines is located in the eastern desert of Egypt, 800 Km south of Cairo and about 25 Km west of The Red sea town Marsa Alam. Sukari gold is well located
More informationCadia Expansion The Impact of Installing High Pressure Grinding Rolls Prior to a Semi-Autogenous Grinding Mill
Cadia Expansion The Impact of Installing High Pressure Grinding Rolls Prior to a Semi-Autogenous Grinding Mill Andy Apfel Maintenance Foreman Tom Waters Plant Metallurgist Outline About Cadia Valley Operations
More informationComminution Circuit Design vs. Feed Size or Mine-to-Mill 2.0
Comminution Circuit Design vs. Feed Size or Mine-to-Mill 2.0 Adrian Dance, PhD, PEng, FAusIMM Principal Consultant Metallurgy adance@srk.com Mill feed quality issues grade lower for all metals hardness
More informationCOMMINUTION CIRCUIT OPTIMISATION
COMMINUTION CIRCUIT OPTIMISATION Maximising Cash Flow for the Existing Asset WHITE PAPER Introduction Orway Mineral Consultants (OMC) is a Perth and Toronto based metallurgical consultancy established
More informationPractise of large scale hematite ore beneficiation
Practise of large scale hematite ore beneficiation Shandong Province Metallurgical Engineering Co., Ltd. E-mail: realzhf@163.com Abstract Shandong Province Metallurgical Engineering Co., Ltd. (hereinafter
More informationResource Efficient Mining Processes of Tomorrow
Metso Process Technology & Innovation (PTI) Resource Efficient Mining Processes of Tomorrow R&D Project Authors: K Duffy W Valery A Jankovic P Holtham www.metso.com General PTI presentation 2014 2015 A
More informationHydrocyclone classification optimization using realtime coarse particles detection in the overflow stream
Hydrocyclone classification optimization using realtime coarse particles detection in the overflow stream Jerin Russell CiDRA Minerals Processing, Wallingford, CT, USA, +1 860 604 9622, jrussell@cidra.com
More informationCommunition Abstract. Fine grind attritional mills; can they or should they go coarser. D Capstick and B Currie
Communition 2012 Abstract Fine grind attritional mills; can they or should they go coarser D Capstick and B Currie Since the introduction of fine grind attritional mills a number of years ago they have
More informationSTACK SIZER TM. Patented Technology. The highest capacity, most efficient, fine wet screening machine in the world
STACK SIZER TM Patented Technology The highest capacity, most efficient, fine wet screening machine in the world Patented Derrick Stack Sizer The Derrick Stack Sizer has redefined the concept of efficient,
More informationGE Intelligent Platforms
GE Intelligent Platforms Optimizing equipment health and processes with GE Data Analytics Software Andre Badenhorst Solution Architect Team Leader (MEA) Mining & Metals The Industrial Internet at GE >5,000
More informationNEW APPROACH ON FLOTATION TAILINGS DEWATERING
NEW APPROACH ON FLOTATION TAILINGS DEWATERING Irena L. Grigorova, Ivan M. Nishkov University of Mining and Geology St. Ivan Rilski, Department of Mineral Processing and Recycling, 1700 Sofia, Bulgaria
More informationTAKING CONTROL OF THE MILL FEED: CASE STUDY - PARTIAL SECONDARY CRUSHING MT RAWDON. Brian Putland, Bernie Siddall and Andrew Gunstone
TAKING CONTROL OF THE MILL FEED: CASE STUDY - PARTIAL SECONDARY CRUSHING MT RAWDON Brian Putland, Bernie Siddall and Andrew Gunstone MET PLANT 2004 CONFERENCE 6-7 September 2004 Perth, WA Contact:Bernie
More informationACHIEVEMENT OF HIGH ENERGY EFFICIENCY IN GRINDING MILLS AT SANTA RITA. *S. latchireddi 1 and, E. Faria 2
ACHIEVEMENT OF HIGH ENERGY EFFICIENCY IN GRINDING MILLS AT SANTA RITA *S. latchireddi 1 and, E. Faria 2 1 OUTOTEC (USA) 6100 Philips Higway. Jacksonville, FL 32216, USA (*Corresponding author: sanjeeva.latchireddi@outotec.com)
More informationDaniel A. Silva Minera Los Pelambres, Salamanca, Chile. Matt F. McGarry ANDRITZ AUTOMATION, Bellingham WA, USA
Streamlining the Steps to Optimized Production: Project Process Modelling, Advanced Control, and Simulator Based Training for Optimized Operation Case Studies Daniel A. Silva Minera Los Pelambres, Salamanca,
More informationPage 1 of 5. Sonar Technology: More than Just a Flow Meter - Leveraging Dual Measurement Capability for Enhanced Value in Industrial Processes
Page 1 of 5 The Power of Passive Sonar Technology by John Viega, CiDRA Beginning in the early 1950s, the United States and British navies began to investigate the use of passive sonar in which an array
More informationHRC : Taking HPGR efficiency to the next level by reducing edge effect
HRC : Taking HPGR efficiency to the next level by reducing edge effect High Pressure Grinding Roll (HPGR) technology has been accepted as an energy efficient alternative to conventional comminution circuits
More informationComminution 2014 ABSTRACT
Grind Circuit Optimization at Rio Tinto Kennecott using real-time measurement of individual hydrocyclone overflow stream particle size enabled by novel CYCLONEtrac SM technology ABSTRACT Christian O Keefe*,
More informationWe are building NEW AITIK. New Aitik. 36 million tonnes
We are building NEW AITIK New Aitik 36 million tonnes MODERN SOCIETY needs the metals Boliden produces. IN THIS CONTEXT, the Aitik mine is of major importance as a reliable supplier of copper, gold and
More informationTwo-stage classification in one unit
CAVEX ReCyclone Slurry Equipment Solutions Two-stage classification in one unit Cavex ReCyclone For many years Weir Minerals have applied their experience of slurry handling technology in the design and
More informationGROSS POWER CALCULATOR
GROSS POWER CALCULATOR General This model uses the equations from Morrell s 1993 PhD thesis: The Prediction of Power Draw in Wet Tumbling Mills. The model is also described in detail in the book Mineral
More informationIPS Inclined plate settlers. Maximum process recovery, minimum plant footprint
IPS Inclined plate settlers Maximum process recovery, minimum plant footprint 1 Beneficiation solutions from Metso In a time when mother earth gives less, it s time to reach further. Metso beneficiation
More informationPAPER # 1882 SYMPOSIUM: MINERAL PROCESSING Mineral Processing of Complex Sulphides
Page 1 of 7 PAPER # 1882 SYMPOSIUM: MINERAL PROCESSING Mineral Processing of Complex Sulphides IMPACT ON MILL DESIGN AND FLOTATION CONTROL OF NEW DISCOVERIES IN THE RELATIONSHIP BETWEEN MACRO AND MICRO
More informationSmarter Washing Solutions AGGST RM 150
Smarter Washing Solutions AGGST RM 150 Modular Wash Range Unrivalled knowledge of our specialist market and a full understanding of customer expectations puts us at the forefront of our field Around the
More informationFlotation cplant: an Optimum Modular Approach
Flotation cplant: an Optimum Modular Approach Pekka Tähkiö and Luis Rudolphy Outotec, Espoo, Finland Corresponding author: Pekka.tahkio@outotec.com Flotation plant design, construction and start-up can
More informationCT425 Optimize Your Process to Make Profits
- 5058-CO900H 1 CT425 Optimize Your Process to Make Profits Rockwell s Model Predictive Control Technology Aaron Dodgson Pavilion Business Development Western Region aadodgson@ra.rockwell.com PUBLIC 2
More informationHannah Yan. Mobile/Skype/WhatsAPP: Wechat:yhr MSP HEAVY DUTY SUMP PUMPS
Hannah Yan Email:info@deponpump.cn Mobile/Skype/WhatsAPP:+86 11 32 3669 Wechat:yhr1381 MSP HEAVY DUTY SUMP PUMPS MSP HEAVY DUTY SUMP PUMPS Vertical, shaft driven centrifugal slurry pumps. Rugged pumping
More informationOUTOTEC FLOTATION TECHNOLOGIES
OUTOTEC FLOTATION TECHNOLOGIES Maintaining recovery and ensuring availability and sustainability while keeping costs under control is challenging. Our tailor-made flotation solutions maximize your return
More informationABB Cement Fingerprint Holistic Approach for Cement Industries
ABB Cement Fingerprint Holistic Approach for Cement Industries Authors: Manish Maheshwari, Chander Kris, Dr. Eduardo Gallestey, Dr. Hans-Helmuth Jung Address: ABB Global Industries and Services Limited,
More informationFor cleaner coal at lower cost. Modular Coal Preparation Plant. Modular Coal Preparation Plant. Classification, cleaning and dewatering
For cleaner coal at lower cost Modular Coal Preparation Plant Modular Coal Preparation Plant Classification, cleaning and dewatering World class coal preparation Proven at the world s most demanding plants
More informationLSA Pump Series - Low maintenance, abrasion resistant for heavy duty service
LSA Pump Series - Low maintenance, abrasion resistant for heavy duty service 2 LSA Pump Series Solutions for Severe Ore and Tailings Slurry Transport GIW Minerals LSA pumps are widely used in ore transport,
More informationDevelopment of an Innovative Copper Flowsheet at Phu Kham. M F Young and I Crnkovic
Development of an Innovative Copper Flowsheet at Phu Kham M F Young and I Crnkovic Phu Kham Location in Laos Phu Kham Plant Layout Plant Layout showing Primary Grinding Rougher Flotation IsaMill Regrinding
More informationInstitute of Quarrying Australia
Institute of Quarrying Australia Crushing Concepts Powerscreen Moira Brady Crushing & Screening Powerscreen Training Academy Project Evaluation Project Evaluation Plant Selection Criteria Applications
More informationGlobal Product Group Cement, CPM Cement. cpmplus Expert Optimizer Designed by process experts, customized to your needs
Global Product Group Cement, CPM Cement cpmplus Expert Optimizer Designed by process experts, customized to your needs ABB s CPM portfolio for cement industries Thermal Energy Economic Process Optimization
More informationIndustrial IT : Optimization for the Cement Industry
Industrial IT : Optimization for the Cement Industry Optimize IT Expert Optimizer courier Optimize IT Expert Optimizer OPTIMIZED PROCESS Application Support Optimize IT Expert Optimizer Training Application
More informationThe Increased Recovery Project at the Phu Kham Copper-Gold Operation, Laos PDR. Authors: A Hoyle, D Bennett, and P Walker
The Increased Recovery Project at the Phu Kham Copper-Gold Operation, Laos PDR Authors: A Hoyle, D Bennett, and P Walker IRP Presentation Summary 1. Phu Kham mineralogy and implications for process design
More informationThe TMAC Resources Inc. Hope Bay Project An Innovative Approach. Gerhard Bezuidenhout
The TMAC Resources Inc. Hope Bay Project An Innovative Approach Gerhard Bezuidenhout Gekko s mission Global Footprint Global & Gold/Silver Focused - increasing coal/polymetallic focus Total 150 staff Team
More informationA CLOSER LOOK AT INCREASING HPGR EFFICIENCY VIA REDUCTIONS IN EDGE EFFECT
A CLOSER LOOK AT INCREASING HPGR EFFICIENCY VIA REDUCTIONS IN EDGE EFFECT Brian Knorr, Metso, York, PA Victoria Herman, Metso, York, PA Devon Whalen, Freeport-McMoRan Inc., Phoenix, AZ Abstract Edge effect
More informationEnergy-Mass-Size balance model for dynamic control of a wet open circuit grinding mill: Part II Simulation tests
ISSN (e): 2250 3005 Volume, 06 Issue, 02 February 2016 International Journal of Computational Engineering Research (IJCER) Energy-Mass-Size balance model for dynamic control of a wet open circuit grinding
More informationNew trends in Process Automation for the cement industry
New trends in Process Automation for the cement industry Author: E. Vinod Kumar, ABB Ltd., Bangalore, India 1. Abstract: Process Automation is an important component of modern cement production. The versatility
More informationABSTRACT INTRODUCTION
Title: Authors: Increasing Capacity of Existing Limestone Grinding Systems While Reducing Grind Size Mr. Gary Harper, Tri-State G&T Association Ms. Melissa A. Hagan, Burns & McDonnell Mr. Paul Dyer, Burns
More informationWET MIX MACADAM PLANT
Where uality is the prime moto! WET IX ACADA PLANT UALITY ENGINEER anufacturers & Exporters of uality Road Construction Equipments. Where uality is the prime moto! Wet ix acadam Plant This Wet ix Plant
More informationHPC-30 Specifications
HPC-30 Specifications For additional information please email us at info@extrac-tec.com Applications Capacity Drive System Electrical Supply Requirements Water Supply Requirements Feed material Trommel
More informationAUTOMATIC CONTROL OF A HIGH TENSION ROLL SEPARATOR
DE WAAL, P. and DU PLESSIS, F.E., Automatic control of a high tension roll separator. Heavy Minerals 2005, Society for Mining, Metallurgy, and Exploration, 2005. AUTOMATIC CONTROL OF A HIGH TENSION ROLL
More informationMOUNT CARLTON COMMINUTION CIRCUIT DESIGN, START-UP AND OPTIMISATION
MOUNT CARLTON COMMINUTION CIRCUIT DESIGN, START-UP AND OPTIMISATION Brian Putland1, Ivka Lovatt2, Andrew Cervellin3 and Daniel Schwann4 Paper Number: 53 1. FAusIMM, Principal Metallurgist, Orway Mineral
More informationMinto Mine. Mill Operations Plan
Minto Mine Mill Operations Plan 2018-01 Prepared by: Minto Explorations Ltd. Minto Mine January 2018 Minto Explorations Ltd. Minto Mine 2018 Mill Operations Plan Table of Contents 1 Introduction...1 1.1
More informationFLSmidth Dorr-Oliver Eimco Flotation Technology. Superior Metallurgy Higher Availability
FLSmidth Dorr-Oliver Eimco Flotation Technology Superior Metallurgy Higher Availability FLSmidth Dorr-Oliver Eimco Flotation Enhance your profits using the combined centuries of technical expertise available
More informationENGINEERING SERVICES
ENGINEERING SERVICES www.elb.co.za Processing Solutions ABOUT ELB ENGINEERING SERVICES ELB Engineering Services (ELB) is an internationally recognised technology driven holistic solutions provider to the
More informationGRAVITY CIRCUIT Knelson Performance, Maintenance, Back to Basics. Drissa ARAMA, Plant Manager
GRAVITY CIRCUIT Knelson Performance, Maintenance, Back to Basics Drissa ARAMA, Plant Manager Morila Mine locality Data for the record Commissioning Oct 2000 Official opening Feb 2001 First bullion bar
More informationIMPROVEMENTS IN SAG MILL THROUGHPUT FROM FINER FEED SIZE AT THE NEWMONT AHAFO OPERATION
IMPROVEMENTS IN SAG MILL THROUGHPUT FROM FINER FEED SIZE AT THE NEWMONT AHAFO OPERATION *Adrian Dance 1, Sonny Mwansa 2, Walter Valery 2, George Amonoo 3 and Bryon Bisiaux 3 1 SRK Consulting (Canada) Inc
More informationFrom copper ore to pure copper with the power of TAKRAF and ABB equipment
From copper ore to pure copper with the power of TAKRAF and ABB equipment Dr. Mario Dilefeld Head of Belt Conveyor Systems Stockholm, 2017-05-03 Copper 2 3 Agenda 1. Introduction Copper used in construction
More informationThe EDEM BulkSim Solution:
The EDEM BulkSim Solution: Maximizing the Reliability and Performance of Conveyor Transfer Equipment A white paper from DEM Solutions Rev. 2.0 CONTENTS INTRODUCTION...2 THE COST OF TRADITIONAL DESIGN METHODS...3
More informationGravity Gold Recovery at President Steyn Mine. P. F. Van den Steen
Gravity Gold Recovery at President Steyn Mine P. F. Van den Steen Knelson Concentrators Africa (Pty) Ltd July 2000 Introduction President Steyn Gold Mine (Freestate) (Pty) Ltd (PSGM) is a privately owned
More informationVXP2500 STIRRED MILL OPTIMIZATION AT CASMYN MINING TURK MINE
VXP2500 STIRRED MILL OPTIMIZATION AT CASMYN MINING TURK MINE *S. Reddick 1, D. Rahal 1, B Hines 1, I. Shah 1 1 FLSmidth Minerals 7158 S FLSmidth Drive Midvale, UT, 84047 USA (*Corresponding author: scott.reddick@flsmidth.com)
More informationThe Impact Wear Behavior of Large Rocks on Slurry Pump Materials and Equipment.
The Impact Wear Behavior of Large Rocks on Slurry Pump Materials and Equipment. Robert J. Visintainer V.P. of Engineering and R&D GIW Industries Inc. Dan Wolfe Sr. Associate Mechanical Syncrude Canada
More informationDeveloping Process Control Standards for Optimal Plant Performance at PanAust Limited
Developing Process Control Standards for Optimal Plant Performance at PanAust Limited D Baas 1, D Bennett 2 and P Walker 3 ABSTRACT This paper describes how Brisbane-based PanAust Limited develops process
More informationAsset Performance Management for Mining
Asset Performance Management for Mining Digital Mine Webinar June, 2016 Imagination at work Industrial Imperative: Redefine the Game Industrial productivity Meets the Digital Twin 4% 1991 2010 1% 2011
More informationOCEANAGOLD PROVIDES AN UPDATE TO HAILE COMMISSIONING AND REVISED COMPANY GUIDANCE
MEDIA RELEASE 26 June 2017 OCEANAGOLD PROVIDES AN UPDATE TO HAILE COMMISSIONING AND REVISED COMPANY GUIDANCE (All financial figures in US Dollars unless otherwise stated) (MELBOURNE) OceanaGold Corporation
More informationPOLYCOM high-pressure grinding roll.
POLYCOM high-pressure grinding roll. POLYCOM high-pressure grinding roll the proven, energy-saving grinding system. Outstanding results are obtained with the high-pressure grinding roll for the comminution
More informationPIN MILLS POWDER PROCESSING TECHNOLOGY: THE STURTEVANT SOLUTION.
PIN MILLS POWDER PROCESSING TECHNOLOGY: THE STURTEVANT SOLUTION. STURTEVANT PIN MILLS THINK VERSATILE. THINK STURTEVANT. Designed to use varying degrees of impact and agitation to process your materials,
More informationIN-PIT CRUSHING AND CONVEYING MINE PLANNING AND OPERATIONS Skillings Mining Review, June 1, 1985 by: Independent Mining Consultants, Inc.
1 IN-PIT CRUSHING AND CONVEYING MINE PLANNING AND OPERATIONS Skillings Mining Review, June 1, 1985 by: Independent Mining Consultants, Inc. Introduction The rising operating costs and declining commodity
More informationCity of San Mateo WWTP Filter Cake System
FLO-LINE TECHNOLOGY (WWW.FLOLINEPUMPS.COM) 11822 Kemper Rd., Auburn CA 95603 Ph 800-255-2933 Fax 530-887-2243 CITY OF SAN MATEO WWTP - FILTER CAKE PUMP SYSTEM City of San Mateo WWTP Filter Cake System
More informationEvaluation of Grade Engineering using Enterprise Optimization. Michael Scott, Nick Redwood
Evaluation of Grade Engineering using Enterprise Optimization Michael Scott, Nick Redwood Who we are Not for Profit Research Organization Site implementation of stepchange innovation Grade Engineering
More informationMetso SmartTag The Next Generation and Beyond
Metso SmartTag The Next Generation and Beyond M Wortley 1, E Nozawa 2 and K J Riihioja 3 ABSTRACT SmartTag is a radio frequency identification (RFID) based technology designed to allow tracking of ore
More informationsepro product catalogue mineral systems mining mineral processing aggregates milling screening scrubbing gravity specialists
sepro mineral systems mining mineral processing aggregates milling screening scrubbing gravity specialists product catalogue sepro mineral systems mining mineral processing aggregates milling sizing -
More informationA PROTOCOL FOR CONDUCTING AND ANALYSING PLANT TRIALS: TESTING OF HIGH-CHROME GRINDING MEDIA FOR IMPROVED METALLURGY
C. J. Greet A PROTOCOL FOR CONDUCTING AND ANALYSING PLANT TRIALS: TESTING OF HIGH-CHROME GRINDING MEDIA FOR IMPROVED METALLURGY C. J. Greet Magotteaux Australia Abstract It is widely accepted that the
More informationMinerals Enduron HPGR High Pressure Grinding Roll
Minerals Enduron HPGR High Pressure Grinding Roll *First choice for energy efficient grinding 1 High Pressure Grinding - proven technology High Pressure grinding has become the go to technology for size
More informationSHEDDING LIGHT ON SECONDARY CRUSHING
Preprint 14-160 SHEDDING LIGHT ON SECONDARY CRUSHING A. Festa, Orway Mineral Consultants Canada Ltd., Mississauga, ON, Canada B. Putland, Orway Mineral Consultants Canada Ltd., Mississauga, ON, Canada
More informationABC of Mine-to-Mill and Metal Price Cycles
ABC of Mine-to-Mill and Metal Price Cycles AusIMM Mill Operator s Conference, Perth 2016 Peter Cameron, Diana Drinkwater, Joe Pease Metal Price Cycles Reflect balance of supply and demand BOOM Reap high
More informationT S X : R M X N Y S E. M K T : R B Y
T S X : R M X N Y S E. M K T : R B Y News Release A p r i l 1 4, 2015 Rubicon s Phoenix Gold Project Commences Mill Commissioning and Remains on Schedule for Mid-2015 Projected Initial Production TORONTO,
More informationEnergy Efficiency Comparison in Fine Grinding in the Mining Industry
Energy Efficiency Comparison in Fine Grinding in the Mining Industry Michel Brissette, M.Sc.A., Ing. VP Metallurgy John Starkey, B.Sc.A., P. Eng. Predident November 13 th, 2013 Outline 1. Fine Grinding
More informationPerformance Audit of a Semi-autogenous Grinding Mill Circuit
Preprints of the 19th World Congress The International Federation of Automatic Control Performance Audit of a Semi-autogenous Grinding Mill Circuit Adriaan L. Haasbroek*, Jakobus P. Barnard**, Lidia Auret***
More informationMining company uses Operations Optimization, powered by Predix, to improve throughput by more than 5.5%
Mining company uses Operations Optimization, powered by Predix, to improve throughput by more than 5.5% Challenge: The company believed that it was losing potential revenue as a result of sub-optimal throughput
More information