Process Control in Metallurgical

Plants: Towards ‘Operational
Performance Excellence’
Plenary lecture (& presentation)


Phil Thwaites P.
P Eng.
(Xstrata Process Support)

Objectives of Automing2008

AUTOMINING 2008 is organized to offer an international forum
where professionals can meet and interact about innovations and
recent developments related to automation applied to mining,
g, py
gy, hydrometallurgy,
mineral p
electrometallurgy, and metal manufacturing.

The objectives
of the Congress
– To promote the interaction of knowledge and experiences about
automation applied on the mining, metallurgical processes, and metal
f t i
– To discuss the emerging developments, identify the technologies
and successful automation practices in the mining industry
– To promote an international network for collaboration and
g among
professionals dedicated to develop,
p, to
technical exchange
operate and to maintain automation systems for the mining industry

Presentation & Discussion Topics

Objectives of AUTOMINING2008
Opportunities …. To consider;
Xstrata Profile & Organizational Structure;
XPS ( Xstrata Process Support);
Definition of ‘Process Control’ & Control Performance;
Importance of Correct Process; Control Objective
XPS Process Control Group;
Elements Necessary for Successful Process Control;
Good Process Control Implementation;
(Some) Enabling Technologies;
(Sandoz) Vision;
Concluding Remarks.

…… to consider
‘Operational Performance Excellence’ requires a solid performance of
the regulatory layer AND process optimisation.
For Plant Operators:

Is your feed stable?
Are your
o r instr
ments calibrated and performing?
Are you aware of wireless instruments (including vibration)?
Is your control system up to date and stable?
Are you in manual or auto control?
Are your Operators acting on alarms or are they nuisance?
Do you understand and accept your process variability?
Are you operating within the design targets and process constraints
(pumps, cyclones, supplies, roasters, furnaces etc.)?
Are you using your surge capacity, …. or running tight level control?
Are y
you at optimum
and are the controls robust?
Are you benefiting from asset management systems?
Are failure / fault detection systems implemented?
Can you make the same product for less energy consumption?

South Africa. Australia. Chile. Xstrata maintains a position in the following major international commodity markets: • copper. . lead. ferrochrome. vanadium and zinc. Papua New Guinea.000 people (including contractors). Xstrata employs more than 50. Headquartered in Zug. gold. Canada. silver. Switzerland. • recycling facilities. cobalt. Colombia. coal. nickel. Germany. Norway. Spain. • suite of global technologies. the Philippines. and • additional exposures to platinum group metals. (some are industry leaders). the USA. Dominican Republic. the UK and the Republic of Ireland. Tanzania. New Caledonia. Brazil. The Group's operations and projects span 19 countries: Argentina.Xstrata Profile Xstrata Plc is a major global diversified mining group. Peru.

Brisbane Australia . Canada XT : Xstrata Technology – Joe Pease – Brisbane. L d UK XPS : Xstrata Process Support – Frank McGlynn – Sudbury.Xstrata Organizational Structure Xstrata Executive Committee X Ni X Cu X Coal XTS XPS X Alloys X Zn XT XTS : Xstrata X t t T Technology h l Services S i – Thras Th Moriatis M i ti – London.

XPS : Process Support Process Mineralogy . . Process Control . Flowsheet/project development using i modeling d li and d piloting. Extractive Metallurgy – Provide high-end extractive metallurgy services.Design.Identify and deliver robust process control technology and engineering solutions. il i Materials Technology gy . procurement and operation. Design implement and optimize mineral processing flowsheets by matching the flowsheet to the mineralogy.Improve p the reliability y of critical equipment through appropriate implementation of well proven materials engineering practices at essential stages of design.

i t .’ plant.’ p ‘Process control is considered as the technology required to obtain information in real time on process behaviour and then use that information to manipulate process variables with the objective of improving the metallurgical performance of the plant. C t l for Control f the th purpose off process improvement.Definition of Process Control (McKee. AMIRA P9L) ‘Process control is a broad term which often means different things g to different p people.

Importance of Control Performance (Emerson) .

’ h’ . and if necessary correct. the condition of the plant as a pre-requisite to control development development. ti Correcting plant limitations should be seen as a first step t in i th the control t l approach. modelling and simulation) i l ti ) tto audit dit th the actual t l plant l t operation. AMIRA P9L) ‘There is a need to determine determine. Techniques exist (plant sampling.Process Control Will Not Correct Inherent Design / Flowsheet Problems (McKee. A good example is the importance of classifier operation and its effect on comminution circuit performance performance.

XPS Process Mineralogy gy 95% Confidence 1. Sample 3. Measure . Optimise Sampling and Statistics PROCESS MINERALOGY 2.

flexible scale. Ideal in combination with conventional flotation for low cost circuit expansions p and higher g concentrate g grades. Experts in tankhouse kh design.high intensity flotation. streams . ISA PROCESS and Kidd Process – producing most of the h world’s ld’ refined f d and d EW copper.XT : Technologies ISASMELT high intensity smelting process with low capital p cost. IsaMill – step change in grinding technology.. ALBION PROCESS – simple atmospheric leaching. JAMESON CELL . To treat low grade or refractory copper streams.. energy gy efficient. Metallurgy improvements from inert grinding media. technology Much higher energy efficiency.

Overall Process Control Obj i Objective Measure Control Optimize Process constraint hi h production higher d ti unnits setpoint lower costs poor control better b tt control time ti best control .

Poor to Optimized Control Best Practise: Necessary y for: ‘Operational Performance E Excellence’ ll ’ .

General Process Control Hierarchy Obj ti Objective F Function ti Cash Optimization Economics Site Plant Optimization Plant Optimization Advanced Process Optimize Stabilize O ti i i Control Optimizing C t l L Loop Control C t l Field / Panel / DCS / PLC Measure I t Instrumentation t ti .Inputs I t / Outputs O t t Economic Return Processes Regulatory Manual .

(ABB) Background for Optimisation I Impact t on production d ti via i lloop structuring t t i Production cost Lower Knowledge Based Expert p Control Degree of Optimisation Multi Variable T h i Techniques Cross-Coupled Cross Coupled Feedforward & Cascade Higher Feedback Lower Higher Production or Quality .

p • Managed from XPS.XPS Process Control Group p & its Business Niche • Complementing site resources. The Goal is: ‘Operational Performance Excellence’ . this is done using: enabling (and appropriate) technologies through the involvement of engineering specialists. • Solutions implemented are based upon: solid control engineering g g practice p and operating p g experience. • Business Niche is: ability to identify and deliver robust process control technology and engineering solutions to Xstrata operations and strategic projects.

Isa Lomas Bayas Alt Altonorte t Koniambo . Isa Cu Smelter Sudbury Raglan B th t Bathurst Timmins Montreal FNA Falcondo Collahuasi Mt.Xstrata Operations Impacted by the XPS Process Control Group • Strathcona Mill • Raglan Mill • Ni Smelter • Nikkelverk • Falcondo • Kidd • Brunswick Smelter • CCR Refinery • Horne Smelter • Alt Altonorte t Smelter S lt • Collahuasi Mill • Pilot Plant Activities • Mt.

Systems etc. People: Control / Process Knowledge Process C t l -> Control Operational Performance Excellence Actions: Support Management. Technology gy Transfer Successes: Results & Examples p .Elements Necessary for Successful Process Control in Mineral Plants Tools: Instruments.

’ . AMIRA P9L) ‘A good implementation requires a well defined operating strategy and an associated control strategy.Good Process Control Implementation (McKee.

(Production) Overall Process Control Objective Measure Optimise constraint higher production setpoint p units As-builts (C (Commissioning) i i i ) Control lower costs poor control better control P&IDs (Basic Eng) best control time Falconbridge Limited .Process Control Control Config.Effective Process Control Cycle (f New (for N P Processes / Plants) Pl t ) Deliverable (Stage) Process Flowsheets & Control Philosophy (Development) Process Opt. (Construction-EPCM) Logic Diagrams (D il d Eng-EPCM) (Detailed E EPCM) .

– XPS has recently implemented a complex controller in a (Concept) control block. Collahuasi and Raglan Mills). ) “In g grinding. While some systems have emerged which provide a reasonable level of control.Enabling Technologies 1. negating the costs of an auxiliary Expert System. is generally g y done using g an Expert p system. and there is considerable scope for further development. Multivariable Controller in a PLC Function Block: SAG feed control. and training / support of this system.. 1999). y – These systems often deliver improved control and 4 to 5% increased throughput (e. development ” . there is still much not understood about the dynamic behaviour of these mills. g control of AG/SAG mill circuits is the dominant area. ( (McKee.g.

Apx: 3” . E.8 x 40 mm 2 5 x 4 mm. Bartsch. 11 November 2005 6 x 15” Krebs GMAX Cyclones Vort: 4. 3 x 8 mm 2- 21-CV-02 Ball Mill 14’ dia.5”.Entire Grinding Controls Focus: (Lib ti efficiency (Liberation ffi i and d th throughput) h t) Wipfrag (Size analysis) A 21-CV-04 ASRi Sandvik Cone Crusher Hydrocone H4800 (250 kW) B 21-CV-06 150 mt Surge Bin Flotation 21-CV-05 21-CV-01 Cyclone Feed Density Control SAG Mill 24’ diameter 24 (2240 kW) 11-CV-03 Underground Storage Bins Cyc CycO/F O/F Density Density by by P/Boxwater water addition P/Box addition DI PI PIC RSP OUT DIC CONSTRAIN circulating load by trimming Cyc Feed Density SP LI LIC Select Logic OUT SY DI H/L Lim Cyc Feed Density by trimming O/F density SP FFE Impact Meter Metso Double Deck Vibrating Screen (8’ x 16’) 1. x 21’ (2240 kW) FI MIC OUT H/L Lim ADJ UST FEED SP OR CYC FEED DENSITY SP DIC OUT Ref: FTC Report ‘ Raglan: Cyclone Density Control’.

SAG Charge Multivariable Fuzzy Controller (Bartsch) Inputs Outputs ((Measurements)) (Set-points) Power Fuzzyfication Charge Impactmeter Granulometry (prediction !) Fuzzy Rules Feed Rate Density (water addn) Crusher Gap De-fuzzification De fuzzification Assays Programmed in existing i i plant l PLCs C Mill Speed .

Crushing Plants Crusher Gap Control: Kidd Mill -> Strathcona Mill -> Raglan Mill Field Device DCS Display (via OPC) .ASRi (Automatic Setpoint Regulation) Sandvik Technology .

Enabling Technologies 2. On-Demand Sampling Automation: Excellent practise is an OPPORTUNITY in our Canadian Mills! .

- Froth camera imaging.Enabling g Technologies g 3. Camera Imaging: - Feed size analysis. - Froth Camera Imaging Technology Optical O ti l System S t for f cathode quality: CSQA: Cathode Surface Quality y Analyzer y (Aplik) 39 .

Velocity (mass pull) changes by over 1000%! 2. Baseline ‘pull’ is 2 only 0.Rougher Level Disturbance Level Setpoint Froth Velocity 1.5 – 1 cm/s! : Level SP too low? .

3.Escondida – Froth Velocity is Cascaded t Control to C t l Fl Flotation t ti Cell C ll ((metso t minerals) i l ) SP Aire SP Velocidad PV Velocidad Escondida: Instalación en la Flotación Primaria Líneas (54 Cameras) Camara SP Nivel Tapon Celda WEMCO .5.

Rotating Equipment – Machinery Health: .Enabling Technologies 4.

916 MHz. Sensor Life: 18 month GITE-322-05-PRE-15 FM FSK. anti-collision algorithm Rev 0 – Fecha 100807 – Página 19 de 29 GITE / DES .Proposed Solution • Electronic Wear Sensor (EWS) embedded in liners and lifters fastening bolts • Main components of the EWS: • Transducer 8-12 levels • CPU (coder & signal processing) statistical filtering • RF Transmitter.. Wireless Instrumentation: HighService INDUSTRIAL SUPPORT COMPANY Business Case 3: Smart Wear Sensor 2.Enabling g Technologies g 5. 1mW.

• Norddeutsche Affinerie.Enabling Technologies – Tankhouses (Outotec) • Kennecott Utah Cu. ‘Used Used as a flow indicator indicator’ . • Boliden Harjavalta Pori Refinery. • OMG Kokkola Chemicals. • Akita Zinc (21 Zn cells). • Boliden Kokkola.

XT’s Kazzinc Project (startup late 2009) .g.Tankhouse Automation & Management System (XT and MIPAC) e.

MPC (Model Based) Production cost Control: Lower Knowledge Based E Expert tC Control t l Several tools are available: – Mintek (FloatStar) – Emerson (DeltaV MPC) – ABB (Linkman.Enabling Technologies (Overall Process Unit Control) 6. Expert Optimizer) – Invensys (Connoisseur) – Honeywell (Profit Suite) – G Gensym (G2) – Prediktor – Metso (Adaptive Predictive Model) Multi Variable Techniques Cross-Coupled Feedforward & Cascade Higher Feedback Lower g Higher .

MVs & DVs Regulatory Control System .Connoisseur ((Invensys) y ) Overview Neural Net Connoisseur Environment Adaptive Cont Non-linear LP Optimizer O ti i C Fuzzy Logic Inferential P Optimal Setpoint Director ec o Calc C c M & MV T Target 454 + S1 − ∑ x + d Model Predictive j Controller Constraint Management D304 349 * L10 (LR or QP methods) CVs.

Sandoz presentation – Laurentian Conference. Collahuasi Mill.g.e. g Kidd Zn .Processes to which MPC has been applied i the in th Mi Minerall P Processing i IIndustry d t (Dr. D. 2004) 12 Nickel Shaft Furnaces (Connoisseur) at Falcondo (2002) Kidd Cu C Smelter S lt (DIY on DCS) – Matte M tt Grade G d Control C t l (2002) Ni Smelter Electric Arc Furnace (Connoisseur) – Fe:SiO2 control (2005) ( ) . June 2006) Xstrata: • • • • • • Roasters (Connoisseur e e.implemented in 1993) Flotation Process (G2/Generalised Predictive Control – GPC) – originally implemented by Noranda in 1999 Flotation Level Control (Mintek .g.

Matte Grade Control Manual Model Identification : Expert p Knowledge + METSIM + HSC to determine Dynamics for an Inferential Model Based Predictive Controller Fe . Matte % Fe Metalization Control Manual 3.Ni Smelter Electric Furnace Auto Calcine + Flux + Revert + Coke + Custom Feed Unmeasured Disturbance: Coke Efficiency AFFECTS: 1. Fe:SiO2 Control Auto 2.

1% overall addition accuracy minute to minute: – Clyde Technologies – Objective to put the Operator in control: • On-line mixing of materials. . Dry Feed and Injection to +/.Enabling Technologies 7. • Bag house collection & removal of drag conveyors. • Injection.

Kidd: Direct Limestone Injection +/.01 -3.76 -0.21 0. • Graph illustrates improved draft controll • Better draft control has also lead to hi h bl higher blowing i rates t Superior Concept Clyde RotoFeed® Inlet Spheri valve Load Cell Inlet Spheri valve Lock Vessel Load Cell Converting Furnace Draft Profile Comparison 4 Isolating Rotary Feeder Conveying Line to Lances Batch Limestone Injection Spheri Valve Continuous Limestone Injection Lower Limit Upper Limit 3 2 Furn nace Draft (mm H2O) Dispense Vessel 31 1 0 Draft Control Improvement Converting Furnace Draft (mm H2O) Batch Injection Continuous Injection Maximum 2.21 Standard Deviation 1.71 -2.1% overall addition accuracy min.99 Average -1. to min.58 -1 -2 -3 -4 -5 Time Series .85 Minimum -4.

Enabling g Technologies g 8. Fans Major Engineering Design Challenge 14 Ni Smelter Blower Suction Control ID Fan ESP SLAG COOLING BEDS ROTARY DRYER BLOWERS AND COMPRESSORS BLOWERS AND ROTARY DRYER COMPRESSORS BINS 2nd CASTING WHEEL REVERB FURNACE CASTING WHEEL BINS CONCENTRATE RECEIVING & STORAGE SHED P-S CONVERTERS CONTINUOUS REACTOR NEW #1 Cv NEW #2 Cv NEW #3 Cv ANODE NEW ANODE FURNACES FURNACE SLAG FLOTATION PLANT Falconbridge Limited . Design Good Draft Control Process control must play an increasing role to better control our off-gas processes.Process Control . • CPS Off-Gas Ductwork Very Long Ducts ~50 m Design is critical for achieving responsive control SULFURIC ACID STORAGE TANKS Fundición Altonorte October 2007 SPRAY PONDS #2 SULPHURIC ACID PLANT NEW #3 SULPHURIC ACID PLANT STACK I.D. Off Gas Controls: • 1.

q p . Asset Monitoring: g p provides real-time asset monitoring. and production processes. and maintenance workflow optimization of automation equipment.Enabling Technologies 9.. (ABB) – Detect D t t health h lth and d performance f conditions diti – Assist in diagnosis g of the p problem – Offer correction recommendations . notification. g. IT assets.p plant infrastructure. p plant equipment. field devices. q p ..

Production Performance. equipment.Plant Equipment: q p • Motors. from field instrumentation. With a correctly configured and installed system. PROFIBUS) .Enabling Technologies Plant Assets IT Asset Condition Monitoring (ABB. - Control Network Asset Monitoring. Emerson. PC. . aggregated. to major plant equipment and processes. Fieldbus.. or process performance and their impending failure. analyzed and compared to historical data to provide advanced warning of degrading device. Field Devices (HART. Network and software monitoring. to IT assets. E&H) ABB System 800xA asset monitors are designed with the flexibility and open standards in mind to support assets of all levels. drives. mills etc. plant information can be collected. Control Loop Asset Monitor. Control Process Field Predictive maintenance then becomes a reality. pumps.

2. Principles for arrangement of Control suites. Control Room Design: There is a recognised standard – mostly unknown to Engineering EPCM Contractors for control room design design. Control room layout.Enabling Technologies 10. 3. 5. Displays and controls …. 4. Principles for design of control centres. . ISO11064: – – – – – 1. Workstation layout and dimensions. etc.

etc. Principles for arrangement of Control suites. Nikkelverk. Principles for design of control centres. 5.r o m (u te n s to p p ) T a r g e t k tr l. Displays and controls ….Production Stage gate Control Room Design ISO11064 – Ergonomic Design – – – – – Update Aug 25th 2004 New Central Control Room at Nikkelverk EPC Update for Stage Gate Approval Committee 1. Workstation layout and dimensions.6 l- n g Ju -0 n Ju ro P 4 4 04 -0 r- ay p A M 4 4 -0 -0 ar eb F M 3 4 -0 -0 n ec Ja D 3 03 -0 v- ct o N 3 3 -0 ep S O 03 -0 l- g u Ju -0 n Ju A 3 3 03 -0 r- ay p A M 3 3 -0 -0 ar eb M 2 3 -0 n Ja F 02 -0 v- ec o N D -0 ct O ep -0 2 2 20 S Anttall alarmer pr. 2. New Central Control Room Location Production Stage gate Update Aug 25th 2004 Alarm handling . Control room layout.. O v n -5 L in e æ r (S u m k t r l.r o m (u te n s to p p )) R/ Oper Oper. 3. updated statistics Sept 02 20 32 36 ER : KL : RS : Mar 04 9 17 21 Aug 04 13 17 17 Target 10 16 18 KL / ER Ope rator Desk T a r g e t A la r m R e d u c tio n s 5 0 % F N A El/Guar El/ Guar d desk 100 S u m k tr l. 4.Status and Target Production Stage gate Update Aug 25th 2004 Project Progress Documentation Average numbers of alarms per hour.r o m 90 E k s k l. time 80 New Central Control Room . July 15th 2004 . desk 70 60 KL/ER operator de sk 50 40 30 4 04 -0 vo N ec -0 ct O ep S D 4 4 /8 -0 04 .

Process Control Enabling Technologies Summary • Enabling Technologies: 1. On Demand Sampling Automation 3. Wireless Instrumentation. y Feed and Injection. • Vision (Sandoz). Camera Imaging. Rotating Equipment – Machinery Health. 2. j Dry 8. 9. Multivariable controller in a block for SAG Mill control. Asset Monitoring. . 5 5. 6. Control Room Design. 4. Model Based Control. Off-gas Handling Controls. 10. • Concluding Remarks. 7.

D Sandoz) 40 35 Soft Sensors FeO 30 Classification for 25 20 Intelligent & “Soft” Sensors Quality Control 15 10 Optimisation & Scheduling 0 20 40 60 Sample No. Dr D. 80 100 Operating Plans120 Management Information Systems Operating Constraints Performance Reports Advanced Process Control Setpoints Conventional Regulatory Controls Early Warning Process Condition Monitors Control System Valve position 40 35 SPE Confidence Limit 30 SPE 25 Conventional Sensors & Instrumentation 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 Time Integrated Condition Monitoring and Advanced Process Control Integration .Perceptive Engineering’s Focus: (Vision – Dr.

– There are many approaches. efficient and safer process to operate. – Process control is more than just tools. – Together Together. • This will result in an easier. . realised minimising process variation and optimising process performance. when what is really required is plant control. • the operations team willing to act / implement / support the implementations. a solid control engineering background / experience and experience. and multiple control systems. – Successful plant implementation is reliant on these together with: • process knowledge. together with numerous ‘advanced control’ packages to select from. instrumentation. robust solutions can be realised.Concluding Remarks – Plant automation is often seen as the project deliverable.

. Organizational structure and human resources are important in achieving ‘Operational Operational Performance Excellence.At present metal prices the results from good control control. and ‘Operation Performance Excellence’ are substantial! ‘Operational Performance Excellence’ requires a solid performance of the regulatory layer AND process optimisation. Excellence ’ Thank you.

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