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Empowering Business in Real-time. Copyright 2010, OSIsoft LLC. All rights Reserved.
CONCENTRATOR DYNAMIC PERFORMANCE MONITORING:FLOTATION FRAMEWORK EXAMPLE
Osvaldo A. BascurOSIsoft, LCC
earze@ara.c
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AgendaOverview of the Mineral Processing
Needs
Forcing Factors and Key MarketDrivers
Dynamic Flotation Framework
Asset Framework Infrastructure
Dynamic Performance Management
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Ore Type 2
Ore Type 1
GRADE
RECOVERY
Optimize Efficiency
Optimize
Recovery and
GradeOptimize Recovery
Optimize Grade
GRADE RECOVERY MAP
Improving Metallurgical Performance
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Early work on Grinding/Flotation Integration, Copper 91.
Bascur,1991, Copper 91, TMS.
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5 Copyright 2010, OSIsoft LLC. Company Confidential.
Together into the new decade.
Access to Mining SCADA on line
Alumbrera, PI System Seminar, Buenos Aires 2001
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6 Copyright 2009, OSIsoft Inc. All rights Reserved.
Mining Grinding Flotation Dynamic
Performance Monitoring and Notification
Nelver Benavides et al, Southern Peru Copper, UC2010, www.osisoft.com
http://www.osisoft.com/Templates/item-
abstract.aspx?id=5120&type=events&cid=
1673&year=2010&industry=All&event=-1
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Profit Based Grinding Controls
Bascur, O.A., 1990, Profit-Based grinding controls, Minerals and Metallurgical Processing, February, pp. 9-15, SME
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Profit Based Grinding Controls, Virtual Sensors
Nelver Benavides et al, Southern Peru
Copper, UC2010, www.osisoft.com
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Dynamic Flotation Froth Experimental
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Flotation Variables Classification
Disturbances
Mineralogical Compositions
Uncontrolled Feed Rate
Uncontrolled Feed Size
Uncontrolled % Solids (pulp density)
Insoluble types
Surface modifications
Grade Variability
Manipulated Variables
Physical
Aeration
Impeller Speed Power
Pulp Level
Conditioning Time
Water Sprinkling Rate
Chemical
Reagent Additions (froth, Collectors,
Modifiers
Point Additions
Ph
Controlled
Recovery (tonnage)
Grade
Circulating Loads
Froth Levels
% Solids
Power Intensity
Measured Physical
Flow Rates
Bubbles Froth
Pulp Densities
Levels
Chemical Assays
Ph, Eh
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Flotation Cell Experimental Setup
Medidor de
Torque
Celdainstrumentada y
conectada a un
sistema
computacional para
la adquisicion dedatos y su control
Celda Denver
de un pie
cubico
modificada con
ventana de
vidrio,
Censores deespuma, nivel,
Muestrador de
espuma
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Flotation Cell Experimental Set up
Bascur, O.A., 1982, IMPC Toronto.
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Flotation Framework
Volume of liquidin the Froth
Volume of Bubblesin the Froth
Volume of Liquidin the Pulp
Volume of Bubblesin the Pulp
FeedQFeed
ijY TQLP
ijYATQ
BP
ijY
PAT
ijK
PDT
ijK
AirQBP
ijY
RQ
EQ
Pulp Phase
Froth Phase
ConcQLF
ijY
ACQ
BF
ijY
AirQ
FAT
ijK
FDT
ijK
LP
VLP
ij
YBP
VBP
ij
Y
LFVLF
ijY BFVBF
ijY
Qs
Two-Phase Flow
Critical Area
Entraintment
And
Drainage
Concentrate
TailingsFeed
Water Addition
Air
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Power, Water Recovery, Impeller Speed (RPM), Aeration and Frother Correlations
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Hydrodynamic Flotation Cell Profiles
Air Hold up vs Air Rate (Frother Concentration)
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Pulp Froth Interface detection
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Dynamic Froth and Pulp Volumes
.d V Froth(t)/.dt = QE + QW - QR - QC.d V Pulp(t)/.dt = Qfeed + QRQE - QT
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Water Hydrodynamics
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Example
Froth IV
DynaF-IV
http://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmvhttp://localhost/var/www/apps/conversion/OSI%20Users%202005/Australia/BubblesN1.EXEhttp://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmvhttp://localhost/var/www/apps/conversion/OSI%20Users%202005/Australia/BubblesN1.EXEhttp://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmvhttp://localhost/var/www/apps/conversion/tmp/scratch_11/dynaf%20for%20email.wmv7/27/2019 Osvaldo Bascur
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PI AF 2.0Asset Templates
Data References Define Attributes
(PI Point, Table Lookup (RDB), Formula, User Written)
Attributes have Units of Measure
Common Template for each Asset Type
improves scalability for the enterprise
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28 Empowering Business in Real-time. Copyright 2010, OSIsoft LLC. All rights Reserved.
Analysis Framework for Grinding and Flotation
Operational Data, Ore Type, Hardness,
Viscocity, Separation index, TransportIndex, % 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.
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29 Empowering Business in Real Time. Copyright 2010, OSIsoft LLC. All rights Reserved.
Cubos de datos
Unidad
Unidad 1
Unidad 3
Unidad 4
Unidad 2
Mineral 1
Mineral 2
Mineral 3
Mineral 4
Material
Tiempo
01:00 02:00 03:00
44.700
44.790
44.700
44.790
44.700
44.790
44.700
44.790
69.030
93.790
69.030
93.790
69.030
69.79069.030
69.790
42.7932
42.840
42.7932
42.840
42.7932
42.840
42.7932
42.840
85.132
85.980
85.132
85.980
85.132
85.980
85.132
85.980
94.110
94.85394.110
94.853
94.110
94.853
94.110
94.853
81.230
81.234
81.230
81.234
85.230
85.23485.230
85.234
Chancado
Flotacin
Molienda
Hidro
Proceso
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30 Copyright 2010, OSIsoft LLC. Company Confidential.Together into the new decade.
Example Concentrator OLAP
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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
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THANK YOU foryour attention
www.osisoft.com