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CIMExcel Software Inc. Slide 1

Mineral Processing Operations Simulator (MPOS). MPOS can be used for multiple purposes including, DCS system checkout, tuning, and FAT for new site operations, and or new or upgraded control systems at existing sites. Control strategy design, testing, and tuning.

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CIMExcel Software Inc. Slide 1

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  1. Mineral Processing Operations Simulator (MPOS) • MPOS can be used for multiple purposes including, • DCS system checkout, tuning, and FAT for new site operations, • and or new or upgraded control systems at existing sites. • Control strategy design, testing, and tuning. • HMI design and testing. • Equipment What-If Analysis. • Operator training for new site startup. • Operator training for on-going continuous improvement. • P2P: Crushing, Stockpiles, Primary Mills, Secondary Mills, Flotation, Tailings, and Plant CIMExcel Software Inc. Slide 1

  2. Mineral Processing Operations Simulator (MPOS) • for operator training facilities • Control Room HMI Displays and Operator Inputs • Control System and Motors • Process Model - Accurate Operating Values and Dynamic Responses • Operator Training Scenarios - Variations in Ore Quality and Failures of Equipment CIMExcel Software Inc. Slide 2

  3. MPOS Factory Acceptance Testing - Configurations Interfaced to PCS HMI and Control Hardware/Software Standalone PCS Operator Interface Operator Interface (simulated) Process Variables Motor Status PID Setpoints and Modes Motor Start/Stop PID Setpoints and Modes Motor Start/Stop Process Variables Motor Status PID Setpoints and Modes Motor Start/Stop Motor Stop/Start Motor Status PCS hardware / software OPC-based Integration DCS and MCC (simulated) MCC (simulated) Control Device Outputs Motor Status DCS Analog Inputs DCS Digital Inputs Control Device Outputs Motor Status DCS Analog Inputs DCS Digital Inputs MPOS MPOS Operator Training Scenarios Operator Training Scenarios MPOS CIMExcel Software Inc. Slide 3

  4. Optimal Mineral Processing Control (OMPC) for Pit-to-Plant Optimization CIMExcel Software Inc. Slide 4

  5. OMPC Input - Output Variables OMPC CIMExcel Software Inc. Slide 5

  6. MPOS - FAT and OTS installations for a large P2P site MPOS CIMExcel Software Inc. Slide 6

  7. MPOS - FAT and OTS for Metal Processing • Copper and Molybdenum Processing Operations MPOS CIMExcel Software Inc. Slide 7

  8. MPOS - Gold Processing Operations • crushing - • primary/secondary grinding • autoclaving • thickening-conditioning • neutralization • carbon stripping • leaching operations • refining MPOS CIMExcel Software Inc. Slide 8

  9. MPOS - Operator Training - Control Room Displays MPOS CIMExcel Software Inc. Slide 9

  10. MPOS - Operator Training - Popup Controls MPOS CIMExcel Software Inc. Slide 10

  11. MPOS - Controls and Trends Display MPOS CIMExcel Software Inc. Slide 11

  12. MPOS - Additional Displays MPOS CIMExcel Software Inc. Slide 12

  13. MPOS - Training Scenarios MPOS CIMExcel Software Inc. Slide 13

  14. MPOS - Completely Configurable MPOS CIMExcel Software Inc. Slide 14

  15. MPOS – Completely Configurable MPOS CIMExcel Software Inc. Slide 15

  16. Stockpile - Feeders Model MPOSCIMExcel Software Inc. Slide 16

  17. MPOS - Semi-Autogenous Mill Model MPOS CIMExcel Software Inc. Slide 17

  18. MPOS - Autogenous Mill Model MPOS CIMExcel Software Inc. Slide 18

  19. MPOS - Pebble Crusher Model MPOS CIMExcel Software Inc. Slide 19

  20. MPOS - Ball Mill Model MPOS CIMExcel Software Inc. Slide 20

  21. MPOS - Cyclone Model MPOS CIMExcel Software Inc. Slide 21

  22. MPOS - Flotation Model MPOS CIMExcel Software Inc. Slide 22

  23. Flotation Cell Level Dynamics Qair 1 L1 Qair i ρ1 U1 Li Qair n Qin V1 ρi Sin Ui z1 Ln Vi ρn Un zi Vn • note, • Vi = valve position • Ui = valve positioner MPOSCIMExcel Software Inc. Slide 23

  24. Flotation Cell Level Dynamics • open loop response Cyclones 5 -> 6 -> 4 -> 5, Air Flow - Flow Ratio Control, Solids Setpoint Control @ 50% MPOSCIMExcel Software Inc. Slide 24

  25. Flotation Cell Levels - Nonlinear Model Reference Modal Control • feed flow dependent cell level setpoint mode time scale: 10 minutes per division, 100 minutes MPOS CIMExcel Software Inc. Slide 25

  26. MPOS - Flotation Cell Level Dynamics and Control relative metal recovery efficiency = Ff Mm Vv Gg Ss Pp Tt Rr Aa Hh F = relative ore feedrate M = relative metal grade V = relative metal grade variability G = relative grind S = relative feed solids P = relative pH T = relative temperature R = relative reagents ratio A = relative air ratio H = relative froth height f, m, v, g, s, p, t, r, a, h are typically in the range of -1 to 1. relative grind = mining operations (blast pattern, charge, ore size, toughness), primary crushing (gap, feedrate), primary grinding (feedrate, steel, water, speed, load, power), secondary grinding circuit (cyclones, water, CFP speed, BM speed) MPOS CIMExcel Software Inc. Slide 26

  27. MPOS - Gold Leaching Operations - Dynamics and Control Wc Auc Wt3 Wt4 Wt5 Wt6 Wt7 Wt8 Wcl Wt2 Aut3 Aut4 Aut5 Aut6 Aut7 Aut8 Aut2 V1 V2 V3 V4 V5 V6 V7 V8 Sf1 Wf7 Wf1 Wd Wf2 Wf3 Wf4 Wf5 Wf6 Wf8 5 7 8 2 4 6 1 3 Auf7 Auf1 Aud Auf2 Auf3 Auf4 Auf5 Auf6 Auf8 ρ4 ρ5 ρ1 ρ6 ρ7 ρ8 ρ2 ρ3 Wcp air2 air3 air4 air5 air6 air7 air8 air1 MPOS CIMExcel Software Inc. Slide 27

  28. MPOS - Process Units • Primary and Secondary Crushers • Stockpile Ore Quality Distribution • Apron and Pan Feeders • Ore Conveyors - Fixed and Variable Speed • SAG / AG Mills - Wear, Steel, Ore, Water, Speed, Power, Load, DE Particle Size • Screen Feed Pump Box - Level and Solids - Fixed and Variable Speed Pump • Screening - Particle Size Distribution • Grinding Mills - Lube Oil Systems • Pebble Crusher - Particle Size Distribution • Ball / Rod Mill - Solids, Speed, Power, DE Particle Size • Cyclone Feed Pump Box - Level and Solids - Fixed and Variable Speed Pump • Cyclones - Mass Flows, Solids, Particle Size, and Partition • Cyclone Sets - Pressure, Solids and Flow • Flotation - Multi-Cell Level Dynamics • Flotation - FE Particle Size, Solids and Flow • Flotation - Air and Reagents Addition and Metal Recovery • Tailings - Particle Size, Solids, Flow, and Sanding MPOS CIMExcel Software Inc. Slide 28

  29. MPOS - Conventional and Advanced Control Loops • Lube Oil Systems • Apron and Pan Feeder Speed • SAG / AG Mill - Feedrate • SAG / AG Mill - Power and Load • SAG / AG Mill - Water Ratio • SAG / AG Mill - Speed • SAG / AG Mill - Water Addition • Screen Feed Pump Box Level • Pebble Crusher • Cyclone Feed Pump Box Level • Cyclone Scheduling • Cyclone Underflow Water Addition • Cyclone Overflow Water Addition • Cyclone Overflow Solids • Ball Mill-Cyclone Circuit Grind Optimization • Multi-Line Ball Mill-Cyclone Circuit Optimization • Flotation Cells - Nonlinear Multivariable Control • Flotation Air and Reagents MPOS CIMExcel Software Inc. Slide 29

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