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MULTIVARIABLE PREDICTIVE CONTROL APPLIED TO

SECONDARY-TERTIARY CRUSHING LINES

Roberto Razzetto Canales - Honeywell Chile

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Agenda

Contents

• Introduction

• Process Features

• Crusher Processes - Control Challenge

• Control Implementation

• Results and Evaluation

• Future Applications

• Conclusion

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Introduction of Company

• The Company operates acopper open-pit mine andprocessing facility in ElLoa province in northernChile, Region II.

• The operation isHydrometallurgical andincludes a SX/EW facility,a 150,000 metric ton-per-day crushed leach circuit.

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HYDROMETALURGIC OVERVIEW

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Move mined ore

and crush into

small size particles

Particle size

continue reduction

in Crushers

Crushers

Leaching

H2SO4

H2SO4

Ore

Mine

Ore is contacted

with Acid

Mass Transfer

Solvent Extraction

Process

Solvent Extraction

Electro wining

Hydrometallurgy Value Chain

Electrowin

Process

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Process Features

• The company has three crunching lines ~2,600Tn/Hr each

one. Each line is composed by Secondary and Tertiary

crushers sub units.

• Process Goal: Keep in synch secondary and tertiary lines.

“Tertiary line doesn„t have to consume faster that the

Secondary line can feed” otherwise all line will shut down.

• Delays because long distance in conveyors.

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Process Diagram - Secondary Crusher

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Process Diagram – Tertiary Crusher

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Crusher Processes - Control Challenge

• Long Delays

• Changes in Ore condition

• Unplanned Downtimes

• Dynamic Optimization Criteria

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CONTROL CHALENGE

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Controller Goals

• Increasing Throughput

• Stabilizing Crusher lines (secondary, and tertiary),

considering the constraints imposed by the Hopper´s levels.

• Compensating delay due to Feeder Conveyor distance in the

secondary and tertiary crushers.

• Changing the Optimization criteria online, based on the state

of the internal crusher shell.

• The Solution: Multivariable Predictive Control - MPC

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What is MPCForeigner Language?*Complex Math?

MPC = Multivariable Predictive Control

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– Through the identification of a

model predicts the process

response.

– Control actions are calculated

based on the predictions and the

desired trajectory future

– Apply the first control action and

the cycle is repeats.

Fundamentals of MPC

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Honeywell Solution Based on MPC. Matrix of

Models including delays are used to generate

predictions, and calculate the future control actions.

Robustness Low sensitivity to modeling errors

or non linearity.

Prioritize the use of manipulated variables,

according to the operational needs of the Process

MPC Honeywell Solution: Profit Controller

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TERTIARY

SECONDARY

Profit Controller Strategy

Feeder

Power

Hooper

LevelFeeder

Feeder

Feeder

Feeder

Feeder

Level

Power

Level

Power

Level

Hooper

Level

Hooper

Level

Manipulated Variable

Control Variable

Stock

Pile

To Leaching

Hopper

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The Solution -PROFIT CONTROLLER

Crusher Lines

Process

Feed Sec (t+1)

Feed Ter A (t+1)

Feed Ter B (t+1)

Feed CR A (t+1)

Feed CR B (t+1)

Feeders (t)

Level s, Powers(t)

Ore Conditions

OCA

OCA: Optimization Criteria Adapter

PROFITCRUSHER

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EVALUATION

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Results and Evaluation

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Results and Evaluation

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APC in MMM Chile

• We have new applications in BHP.

– APC for Tackiness : Tails and Concentrate

– APC in Solvent Extraction – no reference in the past this is the first

Reference.

• Customer is convinced that MPC technology is better than

Expert Systems.

• We are in position to offer a integrated solution Simulation

and APC in one platform.

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THE FUTURE

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Next Applications

• Integrate Fixed Condition Monitoring with Profit Controller in

order to detect changes in Operation Points or changes in

Ore features.

• Incorporate particle size instrumentation in tertiary crushers

• Implement Profit Controller in Solvent Extraction (SX) Units.

• Push the Smart Cathode Production concept

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Production Balance, Downtime Report, Intuition Executive

LEACHPAD

MANAGER

$ B

EN

EF

ITS

TIME

APC BUSINESS PLATFORM

Smart Cathode Production

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Production Instruction

Targets are

converted as new

operation points

to MPC….

Product Pacification - ERP

MES Platform

INTUITION

Advance Process Control

Platform

PROFIT CONTROLLER

TARGETS:•ENERGIA•METALURGICOS

Process Deviations / Reasons

Process & Business working together

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Remote Support Center

Management and

contingency

Metallurgical

analysisLife cycle management

First support levelLife cycle management

Second support level

KPI’s managementAdvanced applications

monitoring

Life cycle management

First support level

Life cycle management

First support level

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QUESTIONS?