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Enhancing Operations with Kennecott's Information Systems

This document presents Kennecott Utah Copper's foundational principles and applications of its advanced Information System, showcased at the OSI Software Users' Conference in April 2000. It covers the functionality and data-driven methodologies used in managing historical and current operations at the Bingham Canyon Mine, including the Pit, Concentrators, Smelter, and Refinery processes. The information system enables real-time monitoring, process optimization, maintenance troubleshooting, and effective scheduling, ultimately supporting production efficiency and decision-making.

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Enhancing Operations with Kennecott's Information Systems

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  1. Kennecott Utah Copper’sInformation System A.E. Lamb, D.J. Sonntag, W.P. Wride 2000 OSI Software Users’ Conference April 2 - 5, 2000 San Francisco, California

  2. Information for Action Historical Data Information System Feedback Kennecott’s Foundation for Excellence

  3. KUC Information System General Information PI System Uses

  4. General Information • Historical (The Hill) • Current (The Pit) • KUC Process

  5. The HillGeneral Information

  6. General Information • Historical (The Hill) • Current (The Pit) • KUC Process

  7. The Pit General Information

  8. General Information

  9. General Information • Historical (The Hill) • Current (The Pit) • KUC Process

  10. General Information KUC Process

  11. KUC Process The Bingham Canyon Mine • Move 300,000+ tons/day • Data collected- • truck movements • tons hauled per truck • crusher parameters

  12. KUC Process The Concentrators • Copperton and North Concentrators • 172,000 tons of ore processed/day • Data collected (14,000 points)- • mill speed and power • throughput and flowrates • online x-ray assays

  13. KUC Process The Smelter • Flash smelting, flash converting technology • 720-lb, 99.5% Cu anodes • Data collected (13,000 points)- • furnace temperatures • flowrates • assays

  14. KUC Process The Refinery • Anode Cu —» cathode Cu in 10 days • Cathodes are 99.99% Cu • Data collected (1700 points)- • electrolytic tank conductivity • anodes’ residence time • equipment status

  15. KUC Information System General Information PI System Uses

  16. PI System • Instrument Interface • Compression Algorithm • User Interface • Plants Operating With PI

  17. KUC Information System General Information PI System Uses

  18. Uses • Operations / Maintenance Troubleshooting • Process Optimization • Process Online Monitoring • Creating Production Reports • Maintenance Scheduling

  19. Uses Operations / Maintenance Troubleshooting • Unusual Caustic Usage • Oxidation-Reduction Potential (ORP) Control Problem

  20. Uses Caustic Valve Operation

  21. Uses Operations / Maintenance Troubleshooting • Unusual Caustic Usage • Oxidation-Reduction Potential (ORP) Control Problem

  22. Uses Faulty Reagent Valve

  23. Uses Working Reagent Valve

  24. Uses • Operations / Maintenance Troubleshooting • Process Optimization • Process Online Monitoring • Creating Production Reports • Maintenance Scheduling

  25. Uses Process Optimization • Monitoring Boiler Pressure Increase • Furnace Process Control Issues

  26. Uses Update Actual Holman Boiler Pressure Graph Holman Boiler Warm-up Curve

  27. Uses Process Optimization • Monitoring Boiler Pressure Increase • Furnace Process Control Issues

  28. Uses FSF/FCF Process Control Issues • Sampling and Process Data Availability • Lack of Feedback Control on both furnaces • Concentrate & Matte Grade Variations to the FSF/FCF

  29. Access Excel Feedback Calculations Data Archiving DDE User Interface (visual basic) CRS Furnace Model Matte, S-slag, C-slag,S-feed, C-feed, DRCon, 040 bin Courier Cu, Fe, S, CaO, SiO2 Temperature PI Database Lab Database Uses Furnace Interface Logic

  30. Uses • Operations / Maintenance Troubleshooting • Process Optimization • Process Online Monitoring • Creating Production Reports • Maintenance Scheduling

  31. Uses Process Online Monitoring • Smelter Hot Metals Operation • Powerhouse Operating Parameters

  32. Uses Process Online Monitoring • Smelter Hot Metals Operation • Powerhouse Operating Parameters

  33. Uses Powerhouse Operating Parameters

  34. Uses • Operations / Maintenance Troubleshooting • Process Optimization • Process Online Monitoring • Creating Production Reports • Maintenance Scheduling

  35. Uses Creating Production Reports • Efficient Use of Manpower • Timely Decision Making

  36. Uses

  37. Uses Creating Production Reports • Efficient Use of Manpower • Timely Decision Making

  38. Uses • Operations / Maintenance Troubleshooting • Process Optimization • Process Online Monitoring • Creating Production Reports • Maintenance Scheduling

  39. KUC Information System General Information PI System Uses

  40. Information for Action Historical Data Information System Feedback Kennecott’s Foundation for the Future

  41. Questions?

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