Roberto Razzetto Canales - Honeywell Chile … · MULTIVARIABLE PREDICTIVE CONTROL APPLIED TO ......
Transcript of Roberto Razzetto Canales - Honeywell Chile … · MULTIVARIABLE PREDICTIVE CONTROL APPLIED TO ......
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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?