Vertimill Predictive Analytics - OSIsoft€¢ Inadequate loading of grinding media in the Vertimill...

© Copyright 2017 OSIsoft, LLCUSERS CONFERENCE 2017 #OSIsoftUCosisoft@

Presented by

Vertimill Predictive

Analytics

Scott Schemmel, Jolene Baker and Wyatt

Keller


Vertimill Predictive Analytics


Soda Ash 101

– Ciner Wyoming, LLC (pronounced jin-ner) is a natural soda ash producer in the Green

River basin in Wyoming

– We refine soda ash from a natural feedstock of sodium sesquicarbonate (Trona)

– Trona was deposited in the basin over a million year period when 4 million year old

Lake Gosiute(\ˈgōˌshüt\ ) became closed off from a freshwater source and the alkali

concentration increased

– To produce soda ash, Trona is mined and calcined to remove water and CO2 to convert

the Trona ore to sodium carbonate aka Soda Ash

2(Na2CO3NaHCO32H2O) → 3 Na2CO3 + CO2 + 5H2O

– Used in

• Glass – 49%

• Chemicals – 27%

• Soap and detergents – 11%

• Flue gas treatment – 3%

• Pulp and paper – 2%

• Water treatment – 2%

• Misc. – 6%


Problem Overview

– Continuous Drum Miners mine Trona ore

– Ore Grade varies throughout different areas in the beds

• Low Ore Grade, below 83%, is referred to as “Bad Ore”

• Variances in Ore Grade can lead to process upsets and unplanned downtime

– Lab analysis provides ore grade after the fact - no real time ore analysis

• Process Operators are “blind” to sections of “Bad Ore”


Problem Overview in Detail

– Trona ore is calcined and then dissolved to separate the desired soda ash from the insoluble impurities

– Insoluble impurities are ground to recover any trapped soda ash and produce a PSD that generates a paste for disposal of the tailings

• The amount and type of insolubles are a direct function of ore rate & grade

• The Vertimill is capable of handling a fixed amount of insolubles

• Variations in ore grade can send too many insolubles to the Vertimill

– The Vertimill can be overloaded when…

• There is too high of a insoluble loading, and/or

• Larger PSD of the insoluble, or

• Inadequate loading of grinding media in the Vertimill

– …reducing grinding effectiveness and ultimately spilling over the top of the Vertimill

When the Vertimill is down 60% of total production is lost


7C26A

12.48 AMPS

GR.CR.7T30:II7C26A.PNT

7C26B

269.63 TPH

GR.CR.CRUSH_CRUSH_MISC:WI7C26B.PNT

7C26C

47.64 AMPS

GR.CR.7T30:II7C26C.PNT

7C24A

14.32 AMPS

GR.CR.7T30:II7C24A.PNT

4821.72 SCFM

GR.U7.7H50:FI7H01V.PNT

Nat. Gas Burner Header

7CS31

28.01 AMPS

GR.CR.7K01:II7CS31.PNT

190.90 DEGF

GR.CR.7K01:TI7K01E.PNT

Dust to 7ES10

7ES10To 7BL01

7CS10

11.52 AMPS

GR.CR.7ES10:II7CS10F.PNT

7ML01A

75.91 AMPS

GR.CR.7ML01:II7A01A.PNT

0

20

40

60

80

100

7T19

136.03 GPM

GR.CR.7ML01:FI7CH01AA.PNT

5T57 and 7T10

1364.78 GPM

GR.CR.7ML01:FIC7CH01AB.MEAS

7P01A

7P01B

32.45 AMPS

GR.CR.7ML01:II7P01A.PNT

48.95 AMPS

GR.CR.7ML01:II7P01B.PNT

343.00 DEG

GR.CR.7K01_BMS:TI7K01G.PNT

7T01

179.99 DEGF

GR.U7.7ML04:TI7RC01.PNT

856.24 GPM

GR.CR.3TH01:FIC7P01G.MEAS

7P01F

7P01G

783.82 GPM

GR.CR.4TH01:FIC7P01F.MEAS

795.24 GPM

GR.U5.5TH01_THCKNR:FIC7P01E.MEAS

To 3TH01

To 4TH01

To 5TH01

5T57264.74 GPM

GR.CR.7ML04:FIC7RC01C.MEAS

198.10 AMPS

GR.CR.7ML04:II7ML04.PNT

7ML04

31.41 AMPS

GR.CR.7ML04:II7P04.PNT

7P04

7MLC04

7P02A

7P02B

7T02

0

20

40

60

80

100

To 5TH02

587.26 GPM

GR.CR.7ML04:FIC7P02A.MEAS

12.56 gpm

GR.U6.6T01_PRIMARY:FI11P01BC.PNT

From Deca

91.54 %

GR.CR.7ML01:LIC7ML01AA.MEAS

64.23 %

GR.CR.7T01:LIC7T01A.MEAS

80.02 %

GR.CR.7ML04:LIC7T02.MEAS

7RC01

7.50 AMPS

GR.CR.7ML04:II7RC01M1.PNT7ML01B

188.73 AMPS

GR.CR.7ML01:II7A01BB.PNT

First Warning Insol Saturation

Second Warning Insol Saturation

Final Warning Insol Saturation

Calculated Ore Rate310.17

1/17/2017 12:49:32 PM1/17/2017 4:49:32 AM

280

320

340

360

380

400

440

Calculated Ore Grade83%

1/17/2017 12:49:32 PM1/10/2017 12:49:32 PM

82%

83%

84%

85%

86%

Calciner

Spiral

Classifier

Problem Overview (2 hour processing time)

Ore BinBelt Conveyor Screw Conveyor

DissolverDissolver

Vertimill


Existing Signals

– Existing real-time data showed that the process was affected by Bad Ore or the Vertimill was not properly loaded with grinding media prior to a process upset

• 10 process data streams presented the best pre-upset visibility

– Patterns in the 10 data streams immediately around upset conditions were not consistent enough from upset to upset.

• Varied in frequency, consistency, and magnitude

– Conventional analytics were not good as preventative warning

• Time consuming application of statistical analytics to filter and refine the data did not work

• Some other method or tool was needed…


Enlightenment

• By chance, we met Crick Waters from Falkonry at a regional OSIsoft event

– Falkonry provides a Pattern Recognition software designed for use by front

line process experts or Subject Matter Experts (SME)

– Trial run POV

• 2 months to repeatable insightful patterns for all 10 data streams

– Falkonry “crunched” our data streams

• Similar operating conditions were grouped and color coded

• No context…yet


Existing signals – New Tools & How They Work

– Adding context - time periods defined for Good and Bad Ore events or inadequate grinding media

charge

• Software found similar patterns to create Bad Ore or Media Charge prediction model

• Ran multiple iterations and tests on the models to confirm validity

– Post validation, applied the model to real-time data flow

• Ever improving predictive model

• Able to be adjusted anytime there are new events


Combining Learned Models

– Best Solution? All 10 data streams in one model (pipeline)…

• Expected to see Bad Ore move through the system in an hour or two…not the case…

– Broke 10 data streams into 3 like process pipelines

• Dry-Burner/Calcining, Wet-Dissolving, and Grinding/Milling-Vertimill

• Detectable Variations

– Insolubles from Bad Ore actually buildup hours before Vertimill affected

• Patterns show buildup of Bad Ore cascading from calcining to dissolving to the Vertimill

• Plenty of time for corrective response versus reactive response

Stage 1 trigger

Stage 2 trigger

Stage 3 trigger


Operationalize

DCS Alarm

Alarm 3 Stage Alarm Real time Ore

Grade

Prediction

PI Coresight™ Dashboard


Benefits

• Operations

– Alarms provide visibility for operators where they were “blind” before

– Confidence to make decisions regarding tonnage flow to run at optimal state

• Business

– Reduce lost tons of production

– Benefits are measurable and significant!

• Technical

– No time spent teaching outside parties process details

• Subject Matter Expert (SME) is directly involved

• “Data science in software” significantly reduces time spent performing data analysis

– Visual Pattern Recognition is relatable and easily interpreted

• Models are easily modified to meet current conditions

– Reduced development and deployment time leads to quicker realization of Revenue Growth and Cost Savings


Lessons Learned

• More than one problem may be revealed

• Iterative process requiring input from many areas of the

process

• Opportunity is knocking…


Picture / Image

RESULTSCHALLENGE SOLUTION

COMPANY and GOAL

Company

Logo

Predictions with the PI System and

Falkonry's Pattern Recognition

Ciner Resources is a leading natural soda ash

producer, and wanted to predict and reduce process downtime.

Difficult to find patterns to use for alarms when combining multiple data sources.

Required a more advanced

pattern recognition

solution.

More detailed insight into

current operation

conditions.

• Recognized upset using PI Coresight

• Unable to capture all instances using tools in PI Asset Framework

• Leveraged Falkonry with PI to identify meaningful patterns

• Detect Bad Ore Grade, Mechanical

issues and Process Anomalies

• Generated Calculators using PI AF

Analytics based on new insights

• Justified hypothesis around abnormal

events


Contact Information

Jolene Baker

[email protected]

SMART Plant Lead

Ciner Wyoming LLC

Wyatt Keller

[email protected]

Process Engineer

Ciner Wyoming LLC

15

Scott Schemmel

[email protected]

Head of IT (CIO)

Ciner Resources

mailto:[email protected]



© Copyright 2017 OSIsoft, LLCUSERS CONFERENCE 2017 #OSIsoftUCosisoft@ 16

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Vertimill Predictive Analytics - OSIsoft€¢ Inadequate loading of grinding media in the Vertimill...

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