Simsmart Products and Services cover: Naval military sector Mining industry General industry. Total Enterprise Wide System Process engineering,

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1 Rev. 4.0 Page 1

2 Simsmart, A Products and turnkey solutions provider for over 25 years for Enterprise Wide Multidiscipline Dynamic Modeling, Simulation and Real Time control in the: Naval military sector Mining industry General industry Simsmart Products and Services cover: Total Enterprise Wide System Process engineering, Total Systems Audit and Performance Analysis to challenge existing design Modelling & simulation and Systems Performance Analysis Real-time Control & Optimization and Training Systems Page 2

3 Total Enterprise Multidiscipline Process Control Dynamic Modeling, Simulation & Real Time Control for: Liquids Gases Ventilation (OMVOD) Other Mine processes including material handling processes, compressed air, mine pumps, hoisting, Milling/Smelting, etc Electrical generation and distribution Controls Propulsion Cause & Effect and decisional logic Page 3

4 MINING FACTS The following facts have forced the mining industry to react vigorously: 1. Electricity costs in most jurisdictions have risen +60% from 2001 to today and rising quickly 2. Energy makes up over 10% of most mines operating costs, the second largest expense behind labour 3. Ventilation accounts for up to 50% of a mine energy cost (Source: Newmont Mining CFO : Gold Companies Mining for Energy Savings. Editorial in the Financial Post, August 24, 2005) 4. Green House Gas/Carbon Emissions costs will be added to financial statements in the future 5. Energy costs can establish the viability of mining new ore zones or the viability of staying in business 6. Air quality and quantity are increasing importance in Regulatory Health and Safety and environmental drivers in all industries including mining 7. New technology to address commercial, operational and Health and Safety matters in U/G mining are fundamental to the industry growth and in some cases, survival. 4 Page 4

5 The Opportunity Typically an underground mine will consume about 50% of the electrical power for the site. Of this underground electricity, 50% is commonly associated with ventilation. Past practice has been to start the ventilation and leave it operate 24/7/365 In remote mines with diesel self-generation, the cost of this power is averaging about $0.23-$0.29 per kwh This energy has a carbon footprint of about 0.7 kg CO2(e) per kwh Typical U/G Mine Annual average cost of ventilation Primary = $0.52 million Secondary = $1.73 million TOTAL = $2.25 million Page 5

6 Underground Mine/Tunneling Ventilation Design / Planning Tool Health and Safety Regulatory Compliance Tool (Auto Archiving) Personnel & Machinery Tracking integration Manual, scheduled and Automatic Air Flow Controls Air Distribution Optimization for Production Enhancement Energy Optimization CO2 Reduction and Carbon Credit Opportunities Page 6

7 SIMSMART S SmartEXEC (OMVOD) General Description Key Words: Proven Over 25 Years Dynamic Real-Time Optimized Optional Mass Balance Up to +/-50% Energy Savings Simsmart s SmartEXEC Expandable Energy Control optimized mine ventilation system (OMVOD), based on PROVEN Simsmart Engineering Suite software, supplements current mine ventilation basic control systems is composed of PLCs (Programmable Logic Controllers) with HMIs (Human Machine Interfaces) with supervisory control establishing a DYNAMIC ventilation demand as a function of REAL-TIME tracking of machinery and/or personnel location and/or physical air flow and air quality monitoring. This demand is OPTIMALLY distributed in the work zones via the mine ventilation network and where the energy required to ventilate is minimized by upwards of (+50%) while totally satisfying the demand for each work zone. The OPTIMIZED mine ventilation system operates on the basis of the standard physical air flow monitoring instrumentation or optionally via a high fidelity mine ventilation predictive DYNAMIC simulation model, of the mine ventilation network along with emulated control equipment such as fans and air flow regulators. This modeling technology is based on the Simsmart s proprietary ENGINEERING SUITE developed over the past 25 years. The optional proprietary ENGINEERING SUITE based model always reaches an AIR FLOW MASS BALANCE where the pressure and density is compensated for depth and accounts for the natural ventilation pressure flows due to temperature differences. One flow is always reconciled with the other. A complete mine ventilation control system may be composed of a hybrid combination of physical and model based control. Some systems may not need a ventilation model at all. OMVOD offers additional control for gas concentration and air temperature. Model setpoints are checked for safety bounds and sent to real physical control equipment via the basic control system. This PROVEN, OPTIMIZED, REAL-TIME DYNAMIC Simulation Model and Live Mine Control is unique to SIMSMART s Solution for mining Page 7

8 Level 1 Auto-configured HMI for surface/remote manual control (fan on-off or VFD speed setpoint, Regulator/damper % opening, Door open / close or % opening) Level 2 Modes of operation and scheduling (time based, event based, on demand, i.e.: pre-blast, post-blast, shift start, high gas concentration) Level 3 Surface/remote auto flow, gas concentration and temperature control (damper, regulator or fan modulation from physical flow measurement) calculation or optional model flow calculation Level 4 VOD (zone in/out gates coverage to full tracking coverage) Implementation and Target Energy Savings $ Up to +/-10%* $$ Up to +/-30%* Level 5 Air flow distribution and surface fans energy optimization * (Estimated Energy Savings based on Mine Data Model Generated Outputs) $$$ Up to +/-50%* Page 8

9 Inputs Mine/Tunnel development plan Mine/Tunnel ventilation layout (plan view and detailed level and draw point views) Equipment list for fans, regulators and machinery and personnel count Energy costs Interviews with operations and ventilation engineering Phase 1 deliverables All equipment detailed parametric and behavioral information Operating scenarios (machinery, shifts, pre-blast, post-blast, scheduling, ) Interviews with operations and ventilation engineering Phase Phase 1 Preliminary Engineering Phase 1a-Scoping Study (+/-30%) Phase 1b-Feasibility Study (+/-10%) Phase 2a SMARTEXEC production detailed engineering Outputs Scoping leading to Feasibility preliminary assessment of the business opportunity, savings, scope and costs of implementing the full SmartEXEC solution with the following deliverables System Requirements Specification (SRS) and project scope Savings Rough Order of Magnitude (ROM) Fixed cost for project phases 2a and b ROM for project cost System Requirements Review (SRR) and acceptance Critical Design Review (CDR) and acceptance Test Plan and Factory Acceptance Testing (FAT) procedures review and acceptance FAT and system acceptance SmartEXEC ventilation model, controls, optimization, scheduling, configuration, HMIs and performance analysis capability Phases 1 and 2a deliverables Physical mine survey Interviews with operations and ventilation engineering Phase 2b Equipment procurement & installation detailed engineering Confirmation of the expected costs of the complete system including installation costs Detailed cost estimate and fixed procurement and installation cost for Phase 3 Phases 1 and 2a and 2b deliverables Phase 3 System installation and startup Procurement, installation, commissioning and training for the VFDs, instrumentation, automation air flow regulators, ABB DCS and integration of SmartEXEC model to ABB control system SmartEXEC integration to the ABB control system System installation, set to work, startup and model adjustments as per ventilation surveys Site Acceptance Testing (SAT) and final system acceptance Installed system Support contract Phase 4 System support Remote and/or on-site support for maintenance and support Troubleshooting assistance Problem resolution Upgrades & enhancements Bug fixes Page 9

10 Implementation level Control Level Description Conventional Control (physical measurement) Model Based Control (calculated measurements) Mine wide mass flow balance with pressure, temperature, density and air resistance as a function of depth Level 1 Manual control: intelligent HMI for surface/remote control (fans on-off or VFD speed setpoint, controllable doors, regulators/dampers) Standard Optional Level 2 (optional) Event and scheduling control: time based, signal threshold, on demand i.e.: flushing, shutdown, pre blast, post blast, shift start, high gas concentration, Standard Optional Level 3 (optional) Flow control, gas concentration and temperature control Standard Optional Level 4 (optional) Flow control via ventilation demand calculation as a function of personnel location and machinery location & operating status (link to tagging & tracking system) (zone in/out gates coverage to full tracking coverage) Standard Optional Level 5 (optional) Optimization control: air flow distribution and surface fans energy Standard Optional Page 10

11 oromvod ventilation model Events and scheduling Regulators, dampers, aux. fans and boosters control Automation System Manual Control and Monitoring Main vent fans VOD Surface fans control Auto flow control Auxiliary and booster fans VOD Auto flow control Minimum flow and other control limits Regulators, dampers and doors Air quality & temp. control Temp Air Flow Gases Instruments Air distribution and surface fans energy optimizers Demand calculation per zone Personnel location Vehicle location and status Tagging & tracking Page 11

12 Re-fit and upgrades Real-time Control & Optimization Deployable System Conceptual Design Training Simulations Requirements Functional and Detailed Design Operational Systems Virtual Testing Product Definition Performance Analysis Validated Systems Page 12

13 OMVOD integrated HMI Integrates tracking, monitoring, controls and optimization Surface, Underground and Web Autoconfigures on mine evolution OMVOD configuration interface: Ventilation layout Fans and regulators Control parameters Machinery Personnel Configuration reports Dynamic Tracking System Dynamic economic control Surface fan energy, scheduling Supervisory control Level air flow distribution, scheduling Optimizing loop control Air flow demand calculation, scheduling Single loop control Fan air flow, regulator air flow, scheduling, Field safety, field interlocks, permissives Measure / Manipulate Air quality, air flow, personnel location, machinery location and operating status, fan speed, regulator position or flow Fans, Regulators, Air flow sensors, Air quality sensors Ventilation process OMVOD real-time engine Tracking integration Air demand calculation High fidelity ventilation model Controls and optimization Scheduling DCS and PLCs Complete OPC Client-Server communication architecture Page 13

14 Model Example of Level 5 Energy Savings of 2,523,475 $/yr (59%)* * (Based on Mine Operational Data Input) $@ cfm 2 3 cfm 2 cfm1 $@ cfm1 q mcpt Page 15

15 The Challenges to Success Challenge Status/Plan Expectations of experienced miners that vents go on and stay on Cultural Change required with ongoing education of overall benefits of Dynamic OMVOD to miners. Emphasize Health and Safety Legislation Mines Inspectors Capital constraints Lack of model certainty prior to embarking on the change Rugged application of fragile equipment Availability of integrated component examples Dynamic Archiving of Air Quality, etc will allow validation or challenge to current Legislation Inclusion in validation and implementation process Initial IRR and ROI validations using the simulation model to confirm business case for Dynamic OMVOD Validate/challenge Simulation Model prior to implementation. 5 level staged implementation approach in effect to ensure certainty Mine proven hardware with redundancy and fail safe software selected and installed Simsmart Dynamic OMVOD Mine installation references available Caveats and Cautions Hot workings with significant residual heat in the rock may rebound too quickly during unventilated periods. Blast gas exhaust Page 16

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17 OPEX Production Today With full SmartEXEC Page 18