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CIMExcel Software Inc. Slide 1

Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization. CIMExcel Software Inc. Slide 1. Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization. Increases Stability and Reduces Variability. Increases Ore Throughput and Metal Recovery.

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CIMExcel Software Inc. Slide 1

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  1. Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization CIMExcel Software Inc. Slide 1

  2. Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization • Increases Stability and Reduces Variability. • Increases Ore Throughput and Metal Recovery. • Increased Throughput 3 - 5 % • Increased Recovery 1 - 2 % CIMExcel Software Inc. Slide 2

  3. OMPC Input - Output Variables OMPC CIMExcel Software Inc. Slide 3

  4. Optimal Mineral Processing Control (OMPC) - Features • Conventional PID with Feedforward Control • Discrete-time Control • Non-linear Model Reference Control • Modal Control • Advanced Hill-Climbing Optimization • Continuous Response Identification and Learning • Model-based Virtual Measurements • Advanced Signal Analysis and Process Variable Filtering • Accurate Dynamic Models for Design and Testing • Implemented in a DCS and a PC (via OPC) CIMExcel Software Inc. Slide 4

  5. OMPC Pit-to-Plant Optimization Variables • Drill Hardness, Blast Pattern, and Powder Factor Tracking • Primary Crusher Discharge Ore Size Distribution • Primary Mill Feeder Ratios • Primary Mill Feedrate • Primary Mill Feedrate - Rate of Change • Primary Mill Solids and Speed • Primary Mill Steel Charge and Size (long term) • Ball Mill Steel Charge and Size (long term) • Ball Mill Solids and Speed • Flotation Solids and Grinds • Flotation Air and Reagents Ratios and Cell Levels CIMExcel Software Inc. Slide 5

  6. OMPC Pit-to-Plant Optimization - Manipulated Variables • Blast Pattern and Powder Factor (long term) • Primary Crusher Gap • Feeder Speeds • Feedrate and Rate of Change • Primary Mill Solids • Primary Mill Speed • Cyclone Scheduling (Active Cyclones) • Cyclone UF and OF Water Addition • CFPB Water Addition • Flotation Air Flow and Reagents Valves • Flotation Cell Level Valves CIMExcel Software Inc. Slide 6

  7. OMPC – Other Features • Primary Crusher Performance Analysis • Primary Mill Performance Analysis • Ball Mill - Cyclones Performance Analysis • Flotation Performance Analysis • Primary Mill Dynamic Response Model • Conventional DCS PID Control Loops with Feedforward • Discrete-time Control Loops • Primary Mill Dual Power-Pressure Control with Ore Quality Feedforward • Stockpile - Feeders Ore Size Classification Identification • Primary Mill Design/Equipment Performance Improvement Analysis • (feed, steel, lifters, liners, grate, motors) OMPC CIMExcel Software Inc. Slide 7

  8. OMPC - Increased Ore Throughput ~ 5% A and B Primary Mills are identical and are fed equally from the same stockpile. A-line has OMPC turned on, B-line does not. A-line averages 951 Tph. B-line averages 901 Tph. OMPC CIMExcel Software Inc. Slide 8

  9. OMPC - Increased Metal Recovery ~ 2 % A1 and A2 Ball Mill - Cyclones - Flotation sides are identical and are fed equally from the same primary mill with the same particle size distributions. A1-side has OMPC - Cyclone Scheduling turned on, A2-side does not. Both sides have OF Density Optimization, Feedforward Air Ratio, and Reagents Flow Ratio turned on. A1-side averages 89.8 % recovery efficiency. A2-side averages 87.6 % recovery efficiency. OMPC CIMExcel Software Inc. Slide 9

  10. OMPC - Integrated Conventional and Advanced Control • Conventional Control (implemented in DCS/PLC via ST): • Ore Quality Analysis • Feeder Speed • SAG / AG Mill Dual Power - Load Control with Feedforward Ore Quality - discrete time • SAG / AG Mill Speed • SAG / AG Mill Water Ratio • SAG / AG Mill Water Addition • SFPB and CFPB Level • Cyclone - Underflow and Overflow Water Addition • Flotation - Air Flow and Reagents Flow • Lube Systems Temperature (with Feedforward) • Advanced Control (external PC via OPC): • Feeder Modal Control • SAG / AG Feedrate, Water Ratio, and Mill Speed • Cyclone Scheduling • Cyclone - Overflow Solids • Flotation - Air Flow and Reagents Feedforward • Flotation Cell Levels - Multivariable Nonlinear Model Reference Modal Control • with Feedforward and Dynamic Observer OMPC CIMExcel Software Inc. Slide 10

  11. OMPC - Primary Mill Control • Ore Quality Analysis and Feedforward Control for Feedrate, Solids, and Speed • Short-term Ore Quality Stabilization • Feeder Modal Control • Advanced Hill-Climbing Optimization for Feedrate, Solids, and Speed • Overload Prediction and Prevention • Grindout Optimization • Ore Load Control Mode • Feedrate Rate of Change Optimization • Feedrate and Power Constraints Mode • Dynamic Grinding Rate Model • Continuous Response Identification and Learning OMPC CIMExcel Software Inc. Slide 11

  12. OMPC – Primary Mill Control and Optimization Grinding Rate Model Overload Prediction Power-Feedrate Constraints Ore Quality Analysis Ore Load Control Advanced Hill-Climbing Ore Quality Feedforward Grindout Optimization Identification and Learning Feedrate rate of change constraints Short-term Ore Quality Stabilization Feeder Modal Control Solids Optimization Speed Optimization Feeder Speed Controllers Primary Mill Water Flow Setpoint Primary Mill Speed Controller OMPCCIMExcel Software Inc. Slide 12

  13. Pit Blasting and Primary Crusher Operations OMPC CIMExcel Software Inc. Slide 13

  14. OMPC - Ore Quality Feedforward Control The Relative Toughness, the current steel load, and the time from the last lifter/liner rebuild are used to determine the Maximum Feedrate. OMPC uses the Maximum Feedrate value as the remote setpoint to the Feedrate Control Loop. The particle size distributions for the relative toughness (RT = 0.8, 1.0, 1.2) are determined from belt cut testing and correlation with the Ore Size Analyzer data. The realtime Ore Size Analyzer data is used to determine the current value of the Relative Toughness. OMPC CIMExcel Software Inc. Slide 14

  15. OMPC - Primary Mill Performance Analysis OMPC CIMExcel Software Inc. Slide 15

  16. Optimal Mineral Processing Control (OMPC) - Primary Mill Analysis and Optimization OMPCCIMExcel Software Inc. Slide 16

  17. Optimal Mineral Processing Control (OMPC) Advanced Hill-Climbing Optimization OMPCCIMExcel Software Inc. Slide 17

  18. Optimal Mineral Processing Control (OMPC) Feeders Modal Identification OMPCCIMExcel Software Inc. Slide 18

  19. Optimal Mineral Processing Control (OMPC) Feeders Modal Control OMPCCIMExcel Software Inc. Slide 19

  20. OMPC - Ball Mill - Cyclones - Flotation Control • Ball Mill Solids - Cyclone Scheduling Hill-Climbing Optimization • for Flotation Solids and Grinds • Flotation Flow - Flotation Air and Regents Ratio - Recovery Efficiency Analysis • (at constant Flotation Solids and Grinds) • Overall Recovery Efficiency Analysis and Optimization • Flotation Air and Regents Ratio Feedforward Control • Multi-line Ball Mill - Cyclone Hill-Climbing Optimization • Ball Mill Overload Prediction and Prevention • Comprehensive Constraints • Cell Levels - Multivariable Non-linear Model Reference Modal Control with Comprehensive Feedforward and Dynamic Observer OMPC CIMExcel Software Inc. Slide 20

  21. OMPC – Recovery Optimization • Cyclone Scheduling and Optimization • Flotation Solids Control and Optimization • Flotation (Air and Reagents) Feedforward Control • Flotation Levels – Multivariable Nonlinear Model Reference Modal Control with Comprehensive Feedforward and Dynamic Observer OMPC CIMExcel Software Inc. Slide 21

  22. OMPC - Model-based Virtual Measurements • Ore Quality • Primary Mill Ore Discharge Rate • Cyclone Size Partition • Flotation Solids OMPC CIMExcel Software Inc. Slide 22

  23. OMPC - Ore Stockpile - Multiple Feeders • Material Transport Model OMPC CIMExcel Software Inc. Slide 23

  24. OMPC – SAG / AG Mill Control and Optimization OMPC CIMExcel Software Inc. Slide 24

  25. OMPC - SAG / AG Mill Advisory Control Mode OMPC CIMExcel Software Inc. Slide 25

  26. OMPC – Ore Quality Analysis OMPC CIMExcel Software Inc. Slide 26

  27. OMPC – Pit-to-Plant Ore Size Reduction OMPC CIMExcel Software Inc. Slide 27

  28. OMPC – Primary Mill Ore Size Reduction Model OMPC CIMExcel Software Inc. Slide 28

  29. OMPC – Ball Mill – Cyclone Models OMPC CIMExcel Software Inc. Slide 29

  30. OMPC – Primary Mill Performance Analysis OMPC CIMExcel Software Inc. Slide 30

  31. OMPC - Pebble Crusher Models OMPC CIMExcel Software Inc. Slide 31

  32. Flotation Cell Levels - Non-linear Model Reference Modal Control Qslurry in Feedforward Leveli Qair i valve position Vj actuator positioner Uj • Level Setpoints • Operator Fixed • Feed Dependent • Startup/Shutdown + + Hysteresis Compensator + ÷ PI fi-1() - Li Solidsin Dynamic Observer Leveli Qair i OMPC CIMExcel Software Inc. Slide 32

  33. Flotation Cell Levels - Non-linear Model Reference Modal Control Cyclones 5 -> 6 -> 4 -> 5, Solids in MANUAL Control, Air Flow in Flow Ratio Control OMPC CIMExcel Software Inc. Slide 33

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