Post on 21-Jan-2016
Kennecott Utah Copper’sInformation System
Kennecott Utah Copper’sInformation System
A.E. Lamb, D.J. Sonntag, W.P. Wride
2000 OSI Software Users’ Conference
April 2 - 5, 2000
San Francisco, California
Kennecott’s Foundation for Excellence
Kennecott’s Foundation for Excellence
HistoricalData
Informationfor
Action
Feedback
KUC Information SystemKUC Information System
General Information
PI System
Uses
General InformationGeneral Information
Historical (The Hill)Current (The Pit)KUC Process
The Hill General InformationThe Hill General Information
General InformationGeneral Information
Historical (The Hill)Current (The Pit)KUC Process
The Pit General InformationThe Pit General Information
Kennecott Annual Production Revenue
Copper
Molybdenum Oxide
Gold
Silver
General InformationGeneral Information
General InformationGeneral Information
Historical (The Hill)Current (The Pit)KUC Process
KUC Process KUC ProcessGeneral InformationGeneral Information
The Bingham Canyon MineThe Bingham Canyon Mine
Move 300,000+ tons/day Data collected-
truck movementstons hauled per truckcrusher parameters
KUC ProcessKUC Process
The ConcentratorsThe Concentrators
Copperton and North Concentrators 172,000 tons of ore processed/day Data collected (14,000 points)-
mill speed and powerthroughput and flowratesonline x-ray assays
KUC ProcessKUC Process
The SmelterThe Smelter
Flash smelting, flash converting technology 720-lb, 99.5% Cu anodes Data collected (13,000 points)-
furnace temperaturesflowratesassays
KUC ProcessKUC Process
The RefineryThe Refinery
Anode Cu —» cathode Cu in 10 days Cathodes are 99.99% Cu Data collected (1700 points)-
electrolytic tank conductivityanodes’ residence timeequipment status
KUC ProcessKUC Process
KUC Information SystemKUC Information System
General Information
PI System
Uses
PI SystemPI System
Instrument InterfaceCompression AlgorithmUser InterfacePlants Operating With PI
KUC Information SystemKUC Information System
General Information
PI System
Uses
UsesUses
Operations / Maintenance Troubleshooting
Process OptimizationProcess Online MonitoringCreating Production ReportsMaintenance Scheduling
Operations / Maintenance Troubleshooting
Operations / Maintenance Troubleshooting
Unusual Caustic Usage Oxidation-Reduction Potential (ORP)
Control Problem
UsesUses
Caustic Valve OperationCaustic Valve Operation
Anodes' Caustic Usage
AnodeCaustic
OffgasScrbr
ScrbDC245BpH
9/20/99 11:00:00 AM 9/20/99 09:00:00 PM10.00 Hour(s)
LIC 527501.OUT
%
AIC 527508.OUT
%
AIC 527510.OUT
%
-250
-200
-150
-100
-50
0
50
-300
150
0
150
0
1502.2801E-002
0.
0.
LIC 527501.OUT
%
AIC 527508.OUT
%
AIC 527510.OUT
%
UsesUses
Operations / Maintenance Troubleshooting
Operations / Maintenance Troubleshooting
Unusual Caustic Usage Oxidation-Reduction Potential (ORP)
Control Problem
UsesUses
Faulty Reagent ValveFaulty Reagent ValveUses
Working Reagent ValveWorking Reagent ValveUsesUses
UsesUses
Operations / Maintenance Troubleshooting
Process OptimizationProcess Online MonitoringCreating Production ReportsMaintenance Scheduling
Process OptimizationProcess Optimization
Monitoring Boiler Pressure Increase Furnace Process Control Issues
UsesUses
Holman Boiler Warm-up CurveHolman Boiler Warm-up CurveUsesUses
Enter Starting Date: 7/6/99 Enter Starting Time: 11:20
Holman Boiler Pressure - Warm Up Curve
0
100
200
300
400
500
600
700
800
900
7/6
/99
11
:02
7/6
/99
11
:16
7/6
/99
11
:31
7/6
/99
11
:45
7/6
/99
12
:00
7/6
/99
12
:14
7/6
/99
12
:28
7/6
/99
12
:43
7/6
/99
12
:57
7/6
/99
13
:12
7/6
/99
13
:26
7/6
/99
13
:40
7/6
/99
13
:55
7/6
/99
14
:09
7/6
/99
14
:24
7/6
/99
14
:38
7/6
/99
14
:52
7/6
/99
15
:07
7/6
/99
15
:21
7/6
/99
15
:36
7/6
/99
15
:50
7/6
/99
16
:04
7/6
/99
16
:19
7/6
/99
16
:33
7/6
/99
16
:48
7/6
/99
17
:02
7/6
/99
17
:16
Time
Pre
ssu
re (
psi
g)
RecommendedPressure (psig)
Actual Pressure(psig)
Update Actual Holman Boiler Pressure Graph
Process OptimizationProcess Optimization
Monitoring Boiler Pressure Increase Furnace Process Control Issues
UsesUses
FSF/FCF Process Control IssuesFSF/FCF Process Control Issues
Sampling and Process Data AvailabilityLack of Feedback Control on both
furnacesConcentrate & Matte Grade Variations
to the FSF/FCF
UsesUses
Furnace Interface LogicFurnace Interface Logic
User Interface(visual basic)
Furnace Model
Access Excel
PI DatabaseLab Database
DDE
Matte, S-slag, C-slag,S-feed,
C-feed, DRCon, 040 bin
Courier Cu, Fe, S, CaO, SiO2
Temperature
Feedback CalculationsData Archiving
CRS
UsesUses
UsesUses
Operations / Maintenance Troubleshooting
Process OptimizationProcess Online MonitoringCreating Production ReportsMaintenance Scheduling
Process Online MonitoringProcess Online Monitoring
Smelter Hot Metals Operation Powerhouse Operating Parameters
UsesUses
Process Online MonitoringProcess Online Monitoring
Smelter Hot Metals Operation Powerhouse Operating Parameters
UsesUses
Powerhouse Operating ParametersPowerhouse Operating Parameters
Factors Affecting STG Steam Temperature
LPStmtoSTGTr SHtrExpStm SH Stm To PH SHtrExitGas Comp#1StmOut HotHexTo1st
3/20/00 09:00:00 AM 3/20/00 11:00:00 AM2.00 Hour(s)
TI 580800
TIC546499B
TI 546458
TIC 546499A.OUT
TI 546438
TIC 546472.OUT450
500
550
600
650
700
400
800
400
800
400
800
0
300
400
800
0
100553.73
664.32
565.34
84.916
456.16
64.631
TI 580800
TIC546499B
TI 546458
TIC 546499A.OUT
TI 546438
TIC 546472.OUT
UsesUses
UsesUses
Operations / Maintenance Troubleshooting
Process OptimizationProcess Online MonitoringCreating Production ReportsMaintenance Scheduling
Creating Production ReportsCreating Production Reports
Efficient Use of Manpower Timely Decision Making
UsesUses
Kennecott Productivity Increase Since 1981 (Tons Copper Produced/Employee)
31
129
1981
Current
UsesUses
Creating Production ReportsCreating Production Reports
Efficient Use of Manpower Timely Decision Making
UsesUses
UsesUses
Operations / Maintenance Troubleshooting
Process OptimizationProcess Online MonitoringCreating Production ReportsMaintenance Scheduling
KUC Information SystemKUC Information System
General Information
PI System
Uses
HistoricalData
Informationfor
Action
Feedback
Kennecott’s Foundation for the FutureKennecott’s Foundation for the Future
Questions?Questions?