earze@ara.

CONCENTRATOR DYNAMIC PERFORMANCE MONITORING: FLOTATION FRAMEWORK EXAMPLE

Osvaldo A. Bascur OSIsoft, LCC
Empowering Business in Real-time.
Copyright 2010, OSIsoft LLC. All rights Reserved.

Agenda
Overview of the Mineral Processing Needs Forcing Factors and Key Market Drivers Dynamic Flotation Framework

Asset Framework Infrastructure

Dynamic Performance Management

Improving Metallurgical Performance GRADE RECOVERY MAP

GRADE Optimize Grade Ore Type 1 Optimize Efficiency

Ore Type 2

Optimize Recovery and Grade

Optimize Recovery RECOVERY

Early work on Grinding/Flotation Integration, Copper 91.

Bascur,1991, Copper 91, TMS.

Access to Mining SCADA on line

Alumbrera, PI System Seminar, Buenos Aires 2001

Together into the new decade.
5 Copyright 2010, OSIsoft LLC. Company Confidential.

Mining Grinding Flotation Dynamic Performance Monitoring and Notification

http://www.osisoft.com/Templates/itemabstract.aspx?id=5120&type=events&cid= 1673&year=2010&industry=All&event=-1

Nelver Benavides et al, Southern Peru Copper, UC2010, www.osisoft.com

6 Copyright 2009, OSIsoft Inc. All rights Reserved.

Profit Based Grinding Controls

Bascur, O.A., 1990, Profit-Based grinding controls, Minerals and Metallurgical Processing, February, pp. 9-15, SME

Copyright 2009, OSIsoft Inc. All rights Reserved.

Profit Based Grinding Controls, Virtual Sensors

Nelver Benavides et al, Southern Peru Copper, UC2010, www.osisoft.com

Dynamic Flotation Froth Experimental

Empowering Business in Real-time.

Copyright 2010, OSIsoft LLC. All rights Reserved.

Flotation Variables Classification

Disturbances
Mineralogical Compositions Uncontrolled Feed Rate Uncontrolled Feed Size Uncontrolled % Solids (pulp density) Insoluble types Surface modifications Grade Variability Physical
Aeration Impeller Speed Power Pulp Level Conditioning Time Water Sprinkling Rate Reagent Additions (froth, Collectors, Modifiers Point Additions Ph

Controlled
Recovery (tonnage) Grade Circulating Loads Froth Levels % Solids Power Intensity
Physical Flow Rates Bubbles Froth Pulp Densities Levels Assays Ph, Eh

Manipulated Variables

Measured

Chemical

Chemical

Flotation Vessel
Moving Cone Air, Qa Two-Phase Flow Area Spray Water, Qs

Concentrate, Qc

Feed, Qf

Aeration Device Tails, Qt

Flotation Cell Experimental Setup

Medidor de Torque

Celda Denver de un pie cubico modificada con ventana de vidrio, Censores de espuma, nivel, Muestrador de espuma

Celda
instrumentada y conectada a un sistema computacional para la adquisicion de datos y su control

Flotation Cell Experimental Set up

Bascur, O.A., 1982, IMPC Toronto.

Flotation Framework
Qs
Q Conc

YijLF

Water Addition
Froth Phase

Q AC YijBF

Concentrate
Volume of Bubbles in the Froth Two-Phase Flow Critical Area

Entraintment And Drainage

K
Volume of liquid in the Froth

FAT ij

FDT K ij

VLF YijLF QR

VBF YijBF

QE
PAT K ij

Q Air YijBP

Volume of Liquid in the Pulp

PDT ij

Volume of Bubbles in the Pulp

Q Air

Air

VLP Y

LP ij

VBP YijBP Pulp Phase

Feed

QFeed Y

Feed ij

QT Y

LP ij

Q AT YijBP

Tailings

Power, Water Recovery, Impeller Speed (RPM), Aeration and Frother Correlations

Hydrodynamic Flotation Cell Profiles

Air Hold up vs Air Rate (Frother Concentration)

Pulp Froth Interface detection

Dynamic Froth and Pulp Volumes .d V Froth(t)/.dt = QE + QW - QR - QC .d V Pulp(t)/.dt = Qfeed + QR QE - QT

Water Hydrodynamics

Example

Froth IV

DynaF-IV

PI AF 2.0 Asset Templates Common Template for each Asset Type improves scalability for the enterprise

Data References Define Attributes (PI Point, Table Lookup (RDB), Formula, User Written) Attributes have Units of Measure

PI Notifications - Configuration

Analysis Framework for Grinding and Flotation

Operational Data, Ore Type, Hardness, Viscocity, Separation index, Transport Index, % Solids, Air Holdup, Flotation and Thickener Hydrodynamics Equipment Status Data Running, Maintenance, Stopped, Down, Troubles Performance Metrics Kwh/ton, Hours Running, Rec/Grade, Tailings, Water Recovery, Consumables, Balls, Reagents, Lime, etc. Min/Max/Stdev, Rate of Change, Totals By Process Line, Plant Area, Process Equipment For an hour, shift, day, week. Copyright 2010, OSIsoft LLC. All rights Reserved.

28

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Cubos de datos

Proceso Unidad 1 Unidad 2 Unidad Unidad 3 Unidad 4 Mineral 1 Mineral 2

44.700 44.790 44.700 44.790 42.7932 42.840 42.7932 42.840 85.132 85.980 85.132 85.980 69.030 93.790 69.030 93.790 85.132 85.980 85.132 85.980 44.700 44.790 44.700 44.790 42.7932 42.840 42.7932 42.840 94.110 94.853 94.110 94.853 81.230 81.234 81.230 81.234

Chancado Molienda Hidro

Flotacin

Material
Mineral 3 Mineral 4

94.110 94.853 94.110 94.853

85.230 85.234 85.230 85.234

69.030 69.790 69.030 69.790

01:00

02:00
Tiempo

03:00

29

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Copyright 2010, OSIsoft LLC. All rights Reserved.

Example Concentrator OLAP

Together into the new decade.

30 Copyright 2010, OSIsoft LLC. Company Confidential.

Further Opportunities: Integration of new measurements

Pulp Level Measurements Accurate Reagent Addition Power Measurements Particle Size Distributions Froth Cameras Mineralogical Composition of Species
(QEM*SEM) Blast Characteristics

Improved Sampling and X-Rays Analyzers

Summary
Drive Operational Efficiency Improve Real Time virtual sensor modeling Improve measurement management. Reduce valuable metal losses. Reduce operating costs. Uncover problems before they affect safety, business, and the environment Timely delivery of validated information to business systems Institutionalize a consistent reconciliation methodology Fuel critical, informed, profitable actions .

Accelerate Decision Making

Enable Performance-Driven Manufacturing

THANK YOU for your attention

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