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APSC 150 Engineering Case Studies Case Study 3

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jadon
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APSC 150 Engineering Case Studies Case Study 3. Part 3 Lecture 3.6 - Process Control in Mining John A. Meech Professor and Director of CERM3 Centre for Environmental Research in Minerals, Metals, and Materials. To Be Ore, or Not to Be?.

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  1. APSC 150Engineering Case StudiesCase Study 3 Part 3 Lecture 3.6 - Process Control in Mining John A. Meech Professor and Director of CERM3 Centre for Environmental Research in Minerals, Metals, and Materials

  2. To Be Ore, or Not to Be? • An ore is a mixture of minerals, one or more of which has value, that can be mined: • At some time • At some place • For a profit • What is not ore today, may become ore in the future • What is ore in one place, may not be in another

  3. Mineral Processing Stages • Liberation (comminution or breaking of rock) • Blasting • Crushing • Grinding • Separation (valuable minerals from waste) • Gravity • Magnetic • Electrostatic • Flotation • Extraction of values from mineral concentrate

  4. Operating Plant Targets • Maximize Product Quantity (Production) • Tonnage rate of ore (say 100,000 tpd) • %Recovery of Valuable Component (say 92%) • Maximize Product Quality (customer needs) • Concentrate grade (say 28 %Cu or 54 %Zn) • Impurity component levels (Bi, Sb, Pb in ppm) • %H2O (both minimum and maximum) • Particle size constraints (top size and ultra-fines)

  5. Grade vs. Recovery • Often, there is a quality/quantity trade-off • One goes up, the other goes down

  6. Process & Instrumentation Diagrams • Process diagrams depict a network of stages or events through which materials flow • Process flowsheets represent unit operations through which solids, liquids, or gasses flow and are transformed • Control system diagrams (or programs) represent stages in a system through which signals, information, or data flow

  7. What is a Process? A Process takes inputs and combines them in a way to produce one or more outputs In process control, only a single input is involved in each block Process Output Input

  8. ≈ ≈ ≈ ≈ ≈ ≈ ≈ ≈ ≈ ≈ ≈ ≈ What is a Process? Process Continuous Batch Discrete Event Discrete State Start Up Non- stop Shut Down after: John Sowa, 2001. Processes and Causality, <www.jfsowa.com/ontology/causal.htm>

  9. Batch or Discrete Process Person Waiting Person gets on bus Person on bus Bus Arriving Bus stops (an Event) Bus waiting Bus starts (an Event) Bus leaving Execution of a Bus Stop Petri Net model (cumulative) - works well with discrete agents/products represented as tokens (an Event) after John Sowa, 2001. http://www.jfsowa.com/ontology/causal.htm

  10. Batch Processes in Mining Drilling Loading Explosives Blasting Digging Loading Ore/Waste Hauling Ore/Waste Dumping Ore/Waste Maintenance Returning Empty

  11. What is a Control System? • A control system tries to keep an important process output variable as close to a target level (or set point) for as much of the time as possible • The system responds rapidly and stably to compensate for changes in other variable that affect the output or to desired changes in the target level of the output set point

  12. Elements of a Control System Load Block System Load Variable Controller Final Control Element Process Error System Set Point + – Control Signal Control Variable System Output Measuring Device Measured Variable

  13. 1.0 1.0 Proportional t=0 t=0 Integral Derivative Elements of a PID Control System Regulator Control One or the Other Load Block System Load Variable Servo Control ? Final Control Element Process Error System Set Point + – Control Signal Control Variable System Output Measuring Device Measured Variable

  14. Response to a Set Point Step Change

  15. Response to a Set Point Step Change

  16. Response to a Set Point Step Change

  17. Response to a Set Point Step Change

  18. Response to a Set Point Step Change

  19. Response to a Set Point Step Change

  20. Response to a Load Step Change

  21. Response to a Load Step Change

  22. Response to a Load Step Change

  23. Response to a Load Step Change

  24. Response to a Load Step Change

  25. Response to a Load Step Change

  26. Unit Operation – grinding • Ball-mill • rotating drum with steel balls cascading onto the rocks to break them into finer particles Grate-Discharge Typical Installation showing Covered Trunnion and associated Electric Motor

  27. Unit Operation – size separation • Hydrocyclone – separation by size

  28. Unit Operation – slurry pump Variable Frequency Drive Slurry Pump

  29. Unit Operation – conveyor belt Conveyor belt feeding a stacker/reclaimer

  30. From crushers Crushed Ore Bin Building a Flowsheet - 1

  31. From crushers Crushed Ore Bin Feed Conveyor Building a Flowsheet - 2

  32. From crushers Crushed Ore Bin Ball Mill Feed Conveyor Building a Flowsheet - 3

  33. From crushers from Mill Water Supply Crushed Ore Bin Ball Mill Feed Conveyor Building a Flowsheet - 4

  34. From crushers from Mill Water Supply Crushed Ore Bin from Mill Water Supply pulp H2O Ball Mill SUMP Feed Conveyor Pump Building a Flowsheet - 5

  35. From crushers from Mill Water Supply Crushed Ore Bin from Mill Water Supply pulp H2O Ball Mill SUMP Feed Conveyor Pump Building a Flowsheet - 6

  36. From crushers from Mill Water Supply Crushed Ore Bin from Mill Water Supply pulp H2O Ball Mill SUMP Feed Conveyor Pump Building a Flowsheet - 7 Hydro cyclone

  37. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply pulp H2O Ball Mill SUMP Feed Conveyor Pump Building a Flowsheet - 8

  38. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply pulp H2O Ball Mill SUMP Electric Motor Feed Conveyor Pump Adding Actuators andFinal Control Elements - 1

  39. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply VS Drive Motor pulp H2O Ball Mill SUMP Electric Motor Feed Conveyor Pump Adding Actuators andFinal Control Elements - 2 VS = Variable Speed

  40. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply VS Drive Motor pulp H2O CS Drive Motor Ball Mill SUMP CS Drive Motor Electric Motor Feed Conveyor Pump Adding Actuators andFinal Control Elements - 3 VS = Variable Speed CS = Constant Speed (to be ignored for this exercise)

  41. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply VS Drive Motor pulp H2O Ball Mill SUMP H2O valve Electric Motor Feed Conveyor Pump Adding Actuators andFinal Control Elements - 4 VS = Variable Speed

  42. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply H2O valve VS Drive Motor pulp H2O Ball Mill SUMP H2O valve Electric Motor Feed Conveyor Pump Adding Actuators andFinal Control Elements - 5 VS = Variable Speed

  43. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply H2O valve VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP H2O valve Electric Motor Feed Conveyor Pump Adding Instrumentation - 1 VS = Variable Speed

  44. From crushers To Flotation Separation Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply H2O valve VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Instrumentation - 2 VS = Variable Speed DP = Direct Pressure

  45. From crushers To Flotation Separation Pulp Density Meter Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply H2O valve VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Instrumentation - 3 VS = Variable Speed DP = Direct Pressure

  46. Particle Size Monitor From crushers Pulp Density Meter Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply H2O valve VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Instrumentation - 4 To Flotation Separation VS = Variable Speed DP = Direct Pressure

  47. Particle Size Monitor From crushers Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Control - 1 To Flotation Separation Pulp Density Set Point + – Pulp Density Meter Pulp Density Controller H2O valve VS = Variable Speed DP = Direct Pressure

  48. Particle Size Monitor From crushers Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Control - 2 To Flotation Separation Pulp Density Set Point + – Pulp Density Meter Pulp Density Controller H2O valve Motor Controller - Sump Level Set Point + VS = Variable Speed DP = Direct Pressure

  49. Particle Size Monitor From crushers Hydro cyclone from Mill Water Supply Crushed Ore Bin from Mill Water Supply VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Control - 3 To Flotation Separation Pulp Density Set Point + – Pulp Density Meter Pulp Density Controller H2O valve - Motor Controller Tonnage Set Point + Motor Controller - Sump Level Set Point + VS = Variable Speed DP = Direct Pressure

  50. Particle Size Monitor From crushers Hydro cyclone from Mill Water Supply Crushed Ore Bin Crushed Ore Bin Crushed Ore Bin Crushed Ore Bin from Mill Water Supply VS Drive Motor Weigh Scale pulp H2O Ball Mill SUMP Sump Level H2O valve Electric Motor DP Cell Feed Conveyor Pump Adding Control - 3 To Flotation Separation Pulp Density Set Point + – Ratio Set Point Pulp Density Meter Ratio Control Pulp Density Controller H2O valve - Motor Controller Tonnage Set Point + Motor Controller - Sump Level Set Point + VS = Variable Speed DP = Direct Pressure