AggFlow Sample Training Agenda

Maximizing Plant Flow Production

& Profitability

______________________________

AggFlow Training Session

Charlotte, North Carolina

February 18-19, 2009

______________________________

Presented by Bob Bartok

Vice President, Paschal Associates

BS Metallurgical Engineering, Illinois Institute of Technology

MBA, Indiana University

Hosted by Brian Lewis

President & Inventor, BedRock Software

Helping Producers Maximize Profitability

Page 2 of 26 Private & Confidential, Subject to change

Day 1 - Agenda

08:15 New User Orientation

AggFlow as a Benchmark

Basic Operations, Selecting Equipment, Connecting Flow Streams, Running the Plant

Sample Problems & Exercises

09:45 Break

10:00 Opening Remarks to Full Training Group

Establishing Goals & Objectives

AggFlow – The Plant Process Benchmark

10:05 Developing a Plant Layout

Getting Started, AggFlow Definitions, Setting User Preferences

Equipment, Flow Streams, Monitors, User Interface; AggFlow Tricks & Tips


12:00 Lunch

13:00 In Depth

Crushers; Database Assumptions; Interpolation of Gradations, Calculation Methods

Screens: Database Assumptions, Calculation Methods, Screen Area Efficiencies

Running The Plant; Red Flags, Maximizing Plant Flows, Applying Specifications

Reports, Graphs, Using Color & Making Notes on Worksheets


14:45 Break

15:00 Advanced Features

Apply specifications, Modes, Blending, Dust Calculations and Conveyors

Creating Multi-page Plants, Importing & Exporting to Excel, Internet Features


16:30 Day 1 Wrap-Up and Q&A

17:30 AggFlow Management Team Reception



Day 2 - Agenda

08:15 Day 1 Review

Developing a Plant Layout, Crushers, Screens, Reports & Graphs, Advanced Features

08:30 Wash Equipment

Sand Screws, Classifying Tanks, Cyclones & Separators, Black Box


09:30 Water Mass Balance Calculations

Using Water in a Plant, Pumps, Water Pipes, Slurry Pipes, Adding Water Sources,

Spray Bars, Use of Water in Product, Clarifiers & Thickeners, Water Loss


10:45 Break

11:00 Measurements

Sample Buckets, Belt Scales, Measuring Flow Rates & Gradations

Measuring Crushers, Screens, Stock Piles and Validating Calculations in Plant Data


12:30 Lunch

13:30 Fine-Tuning Your Calculations & Plant Designs

Calculation Levels 1, 2 & 3

Bottlenecks AggFlow Cannot Account For

14:30 Final Steps to Improve & Increase Production

Establishing Benchmarks

Comparing Measured Values to Calculated values

Screens, Crushers, HSI’s, Cones


15:30 Day 2 Wrap-Up and Q&A

14:30 Departure



New User Orientation

AggFlow As A Benchmark

Gradation Definition

AggFlow Equipment Categories

Placing Equipment On The Worksheet

Selecting & Adjusting Specific Equipment

Connecting The Equipment With Flow Streams

Apply Monitors To See Results

“Run” The Plant

Your Best Resource: Select Help, then Open Manual

Simple Plant Setup

Example #1: Setup and Experiment a Simple Plant

Users Around the Globe

Employ AggFlow for:

Total Plant Flow

Simulation & Analysis

Aggregate Mass Balance

Calculations

Water Mass Balance

Calculations

Independent Equipment

Selection

Conduct “What-If?”

Scenarios

Experiment with Different

Equipment & Settings

Switch to Different

Operating Modes

Instantly

Justify New Investment

by Comparing Set-ups

Fine-Tune Equipment

Operation

Identify Plant

Inefficiencies &

Bottlenecks

Reduce Calculation Time

Improve Fuel

Consumption &

Emissions

Customize Plant

Calculations and Reports



Introduction To AggFlow

BedRock Mission: Help Producers Maximize Profitability

Review processes in existing plants; Find plant process & production bottlenecks

More TPH from same equipment

Assist in correct equipment choices

Accurately target plant production and product mix to meet sales forecast

AggFlow History

Story of the thumb that controlled profitability

Continuous development since 1993

Currently employed in 63 countries

Installed on your computer is the latest version of AggFlow (200811)

Includes Water Mass Balance Calculations & French/Spanish Translation

In This Training Class

We encourage interaction and discussion with your neighbor

We welcome feedback, suggestions & observations during the class

Please do each sample as it will be expanded upon throughout the class

Feel free to repeat and experiment with different options in the samples

OUR GOAL: Tomorrow Afternoon You Will Be Highly Proficient Using AggFlow

Make AggFlow your plant process benchmark

Layout any type of plant

Identify and resolve bottlenecks

Make AggFlow accurate for your plant

Know what questions to ask to improve overall efficiency

Produce plant files, equipment and production reports & graphs

Optimize Plant Production and Maximize Profitability



Developing A Plant Layout

What AggFlow Is & What AggFlow Is Not: How To Use This Tool

Benchmark

Extremely Sophisticated Calculation Tool (Aggregate : Water)

AggFlow is not artificial intelligence – It does not think for itself

What You Need to Start Using AggFlow:

Initial feed gradation

This is hard to measure given the sizes are typically larger than 8 inches. The most important factor

in the feed gradation is the value passing the first screening point. For example, if the feed is going to

a grizzly feeder with a 5 inch bar opening, then you want an accurate value for the 5 inch percent

passing value.

Example #2: See: Feed Source Secondary Surge Pile Gradation.pdf

Major equipment in the plant

Note: AggFlow plant flow calculations can be performed with or without modeling the conveyors.

Crusher makes, models and settings

Screen sizes and mesh openings

Overall flow of material through the equipment in the plant

AggFlow Menu Definitions

File Edit View Run Database Selected Object Summary Modes Windows Help

Setting User Preferences

User Units Washing Screen Area Display Titles Lines-Grid Tolerance

Display Size Ranges Saving The Plant HTTP Setup Update

Create a Plant From The Hand Drawn Flow Sheet

Example #3: See: Rough Sketch.pdf



Developing A Plant Layout (continued)

Equipment Placement & Layout

Effect of initial feed on plant accuracy

Equipment descriptions - top level

Flow Stream Layouts

Initial connections

Adjusting bend points

Orthogonal lines

Add Monitors To See Results

“Run” The Plant

User Interface

Zoom features

Multiple selections using shift key

Copy/paste blocks

Graphical Undo

Plant Configuration Advisor – How to use it

AggFlow Tricks

Multiple windows can be open at once

Read the bottom panel for information!

Always keep your program updated

Use your best resource – Open the manual!



Crushers

Crusher Database Assumptions

Model Selection

Manufacturer limits

Book gradations

Interpolation of Gradations

Reduction Ratio Monitoring

Calculation Method

You are in complete control of the output gradations. AggFlow does not calculate automatically.

AggFlow does not calculate an output gradation based on changes to input gradations

You must specify the output gradation by adjusting the equipment set-up in the program

AggFlow actually ignores the input gradation and relies completely on your output specifications

AggFlow does pay attention to the incoming flow rate and ensures mass balance

Some Impact Crushers Track Input Size Range

Sample of Making Larger Rocks Out of Smaller Rocks

Put sand and gravel into a jaw

Example #4: Sand to Jaw

Example #5: Bad HSI



Crushers (continued)

Common Mistakes

Modeling mistakes

Not sized correctly

Not set correctly

Operational mistakes

Not maintained

Not fed correctly (Crushers & Screens)

Not loaded near capacity

Book crusher data not correct for equipment application



Screens

Vibrating Screen Database Assumptions

Model Selection

Adjust as needed

Add new size to database

Calculation Methods

VSMA

Open VSMA sheets

Cedarapids

Deister

Scalper calculation

DBD discussion & efficiency

Screen Area Efficiency

Screen carry over

Set specific size

Adjust sizes and screen efficiency

Refer to results to investigate effects of size and efficiency changes

Using Screen Efficiency To Model Different Mesh Openings

Using the screen efficiency override method



Screens (continued)

Missing from VSMA

Non-wire deck area requirements

Open area adjustment

Varies from one manufacturer to the next

Multi-openings same deck

Non standard screens

Pep screens

Banana screens

Refer final design to manufacturer

Common Mistakes

Modeling mistakes

Not sized correctly

Equipment not set-up correctly

Other constraints; conveyors, chutes and feeders

Misapplication of equipment

Operational Mistakes

Equipment is not maintained

Screen is not fed correctly

Screen operating parameters

Wrong media

Wrong flow direction

Water amounts

No correction for screen operational parameters

Under loaded screens

Example #6: Under Loaded Screen



Running The Plant

Red Flags

Note: AggFlow highlights problem areas and equipment exceeding warning levels by turning the

equipment in the worksheet red. However, the program will continue to perform calculations as if there

was no problem. Therefore, you can choose to address, or ignore, red flags at anytime.

Warning Levels

Three warning levels:

Alarms; AggFlow alerts you when calculated results may not match field results

Warnings; Items to be aware of, will not likely affect calculations or results

Missing Limits; Manufacturers have not supplied crusher limits and AggFlow has no limits here

Example #7: Warning Levels

Maximize Plant Production Feature

Runs the plant to maximize crusher capacities

Does not take into account screens & conveyors

Apply Specifications

Product Mix



Reports, Graphs, Using Color & Making Notes on Worksheets

Saving Settings

Save multiple files (unlimited)

AggFlow View Results defaults to last view saved

Automatic Save (set time period in User Preferences)

File Recapture – in a system crash, AggFlow will provide the option to recapture/save unsaved files

AggFlow File Protection

Turns the Specific AggFlow worksheet into read only (find it under FILE, then Protection)

3-Deck Screen Example

View results & reports for a 3-deck screen.

PDF Reports

Worksheet and results

Title Block Info

Company and name stay with sheet

Run version – identifies the last time the plant was run in the printout

Spreadsheet Reports

Provides complete report and equipment list in spreadsheet format

You can select individual or a selection of line items (hold the SHIFT key)

Coloring and Making Notes on the Worksheet

Highlight, color and make notes on the worksheet



Advanced Features

Apply Specifications

Specification database

Example #8: Goal - Figure out how to get sample to meet spec

Modes

Modes allow unlimited number of plant setups within each plant file

Example #9: Goal 1 – Use Modes to optimize the same plant for two different products

Example #10: Goal 2 – Use Modes to add a splitter and a new crusher to an existing plant

Blending

Simple Blend Demo

Linear programming info

Example #11: Goal – Determine how many products this plant can make

Dust Calculations

Example #12: Simple Dust Example

Conveyors

Calculation methods

Example #13: Simple Conveyor Example



Advanced Features (continued)

Creating Multi-Page Plants

Linking Pages

Review of Equipment That Can be Linked

Looping Back to First Page

How Big Can Plants Get?

See: bigPlant.pdf

Example #14: Split plant into three pages

Monitor “Layers”

Example #15: Monitors - Create a TPH and a Settings Monitor Layer

Import/Export to Excel

Example #16: Export AggFlow data to Excel, change it, Import the data back to AggFlow

Internet Features

Get Automatic Updates (regularly!)

Send emails & plant files from within program

Automatic error reporting

Send plant files directly to AggFlow Team for review/help

Send support requests and suggestions to AggFlow Team from within program

Create PDF, JPEG and TIFF files

DAY 1 Wrap-Up – Q&A



Day 1 Review

Developing a Plant Layout

Initial feed gradation; Major equipment in the plant; Crusher makes, models & settings; Overall

flow of material; Equipment & flow stream layouts; Monitors; Running the plant; Customizing

AggFlow with user preferences; Reports & printouts.

Crusher Selection

Database assumptions; Model selection; Reduction ratios; Calculation methods; Common modeling

and operational mistakes.

Screens

Database assumptions; Model Selection; Calculation methods; Screen area calculations &

efficiencies; Calculation methods; Common modeling and operational mistakes.

Running The Plant

Red flags; Warning levels; Running with Screen area adjustments; Product mix.

Reports & Graphs

Saving settings; PDF reports; Titles & printout labels; Spreadsheet Reports.

Advanced Features

Applying specifications; Modes; Blending: Dust calculations; Conveyors; Multi-page Plants; Monitor

Layers; Importing/exporting to Excel; Internet Features.



THIS PAGE INTENTIONALLY LEFT BLANK FOR NOTES:



Wash Equipment

Sand Screw

Basic operation and AggFlow simulation

Classifying Tank

Cyclones & Separators

Black Box – Dewatering Screen

Example of Creating a Wash Plant

Example #17: Create a Wash Plant from Sketch



Water Mass Balance Calculations

Using Water in an Accurate Plant

Input water into feed

Converting flow streams to slurry pipes

Adding Water Sources

Screen spray bars

Use of water in product

Fresh Water Piping

Pumps

Clarifiers & Thickeners

Water Loss in an Accurate Plant

Example of Creating a Plant with Water Mass Balance Calculations

Example #18: Add Water Mass Balance Features to Wash Plant



Measurements

Sample Buckets

Quality Control Samples plugged in the flow calculations

Example #19: Install Sample Buckets

Example #20: Demo Excel Interface

Belt Scales

Example #21: Install Belt Scales

Measure Flow Rates and Gradations

Feed material gradation

Variability in feed gradation and making it accurate

Flow Rate

Typical Flow

Primary in-feed not measured

Optimum Flow

Detailed gradation below 4 to 7 inches

% of oversize material

Crushers

Typical

None

Optimum

Input gradation

Output gradation



Measurements (continued)

Screens

Typical

None

Optimum

Output gradations

Stock Piles

Typical

Gradations

Optimum

Gradations and rates

Methods to Validate Calculations with Plant Data

Statistical history

Field measurements

Observations

Example #22: Real Life Examples of Measurements



Fine-Tuning Your Calculations & Plant Designs

Why Do So Many Operations Continue Along With Known Bottlenecks?

Calculation Levels

Level 1

Setup with generic data

If you have average material with standard compression crushers this gets you to level 2

If you have impact crushers you may or may not get to level 2

Data varies greatly from one manufacturer to the next

You may need crusher samples to get past this point

Results may be off - but experts report that incremental change is usually very good

Level 2

Take plant measurements to verify results

May identify problems

Experienced aggregate manager uses this model to identify improvements and problems

Level 3

You have enough data to totally optimize production with accurate results

You reach a point where "what if" calculations are consistently accurate and reliable. Use your

experience to estimate where that point is.



Fine-Tuning Your Calculations & Plant Designs (Continued)

Bottlenecks AggFlow Cannot Account For Or Calculate

Material From the Pit

Transport Equipment

Feeders

Stock Pile Capacity

Surge Pile Capacity

Segregated Material Flow

Transfer Chutes



Final Steps To Improve & Increase Production

Establish Benchmark

Example #23: Sample Plant File

Example #24: Determine Bottlenecks

Compare Measured Values to Calculated Values

Actual settings do not match current design

Make sure crushers as doing as expected

Screens

Monitor efficiency

Size adequate?

Change mesh openings

Lower rate

Crushers

Try to maintain design capacity

Example #25: Sample File Reviews

Example #26: Evaluate Sample for Accuracy

HSI With Standard Data

Cone With Standard Data

DAY 2 Wrap-Up – Q&A







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