Canadian Institute of Mines Metallurgy and Petroleum

Peru Branch ICM-Per

Jueves Minero, IIMP Lima-Peru

Manual Control, Process Automation or Operational Performance

Excellence? What is the Difference?
By Phil Thwaites
CIM Distinguished Lecturer
 CIM
Distinguished Lecture
Lima, Peru Branch May 2013

Manual Control, Process Automation or

Operational Performance Excellence?
What is the Difference?
by Phil Thwaites, 2012-2013
(XPS GlencoreXstrata; www.myxps.ca)
pthwaites@xstrataps.ca; 705-699-3400 x 3463
XPS, Our Global Reach .

XPS has provided support to clients in

+22 countries around the world Finland France Norway Romania
First Quantum DATC FNA Carpathian

Russia Spain Sweden

Silver Bear CLC ADZ Boliden
U.S.A.
Sweden
Norway Finland
Canada Russia
Canada
AuRico Avalon
Bell Copper Blue Coast Romania
France Kazakhstan
Cliffs GWMG
Saskatoon HBMS Spain Kazakhstan
Raglan Regina U.S.A.
Kazackmys
Sudbury Timmins
Toronto Vancouver
Montreal Teck Coal Mexico
Bathurst Vale Dominican Republic
Fire River Gold Eritrea
New Caledonia
Koniambo
Dominican Republic
Ivory Coast
Falcondo Papua New Guinea
Frieda River
U.S.A. Botswana DRC
Avon Bala Cynwyd BCL
Freeport Newmont Tanzania
Brazil Papua New Guinea
Peru
DRC
Mexico Kamoa New Caledonia
Farallon
Botswana
Eritrea Australia
Sunridge
Argentina
Pan American Silver South Africa
Ivory Coast
Chile Australia
Xstrata
Brazil Bundoora Brisbane
Argentina
Belo Horizonte Cosmos Kagoorlie
Tanzania
McArthur River Mt. Isa
Kabanga
Chile University of Queensland
Collahuasi Lomas Bayas
South Africa
Alto Norte Antofagasta
Eland Brits
Codelco
Platreef Sandton
Peru
Antamina Candente

3
CIM Lecture - Introductory Remarks
Konigsman (Noranda) - VP Engineering & Projects to Lynch
Konigsman, 1992; Foreward:
Text Book A Practical Guide to Process Control in the
Minerals Industry {by Flintoff and Mular}

Process control is now an essential part of any concentrator operation.

It provides a proven vehicle for improving operation economics by
increasing revenues and reducing costs.

The question one must ask is whether we are tapping the full
potential of this technology? The answer: ...... is No!
[MITEC Mineral Processing Technical Advisory Committee (TAC), whom acknowledged 2 problem areas:
1) small plant & 2) those plants who use some control but not achieving maximum benefit.]

I agree and say we can do MUCH MORE and be More Efficient

..... as I will present!

Alban Lynch, (founder of the Julius Kruttschnitt Mineral Research Centre in Brisbane, Australia), Oct. 2012:
Control is not a high priority here (Australia) even though the effect of
inadequate control on the loss of mineral tailings is obvious.
Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Discussion topics include:

Control Engineering, as applied to Process Control:
Process Variability, Control & Process Optimization
Control Solutions from Manual control & operation
Control Loop, Applications & Tuning Impacts
The Technology, Important Aspects, System Selection
Automation and Advanced Control
Elements Necessary for Success
Instrumentation Solutions .. To Be Aware of
Operational Performance Excellence:
Examples selected are: Flotation Level Control / Reagent Control
Asset and Performance Monitoring
Opportunities . for You; and for Your Plants to Consider
Process Automation
What is it?
Process Automation is understood, in a wider sense, to include:
measurement and instrumentation
process modelling and simulation
process monitoring and data reconciliation
data mining and multivariate statistics
fault diagnosis and fault tolerant control
process control, monitoring of product quality & control performance
off-line and on-line process optimisation
AI (Artificial Intelligence) methods:
expert systems, neural networks, fuzzy control
sequencing

In other words a very large, and fascinating field!

..... Ideal for a Control Engineer!
Definition of Process Control
(McKee, AMIRA P9L); 1997 Review

Process control is a broad term which often

means different things to different people.

Process control is:

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.

Control for the purpose of operations and process

improvement!
Process Control XPS
As we have practiced for over 3 decades

Measure Control Optimize

Process constraint

higher production
units

setpoint

lower costs

better
poor control control best control

time
Poor to Optimized Control

1.Measure 2.Control

Best Practice:
Necessary for:
Operational
Performance
Excellence

3.Optimize
 Effect of 115sump
on grinding (COFD & RMF)

limit

Must Correct
Plant
Processing
Problems
First!!
Process Control Objectives Summary

Management of TOOLS & RESOURCES to:

Minimize Process Variation
Optimize Process Performance
Minimize (Variable) Costs
Tied to the
Control Product Quality Business
Objectives!
Maximize Safety
For operational performance excellence whatever it takes
Rougher Control and move from Manual
Control to individual Cell Air Control

. and preparing for Optimization

One air supply for two flotation cells: Updated to:

Manual control Individual air flow control to each cell
Air supply blockages
Measured and control in engineering units
Uneven levels
Control Technology Options

Manual Control usually acting on valve position (i.e. % opening, or motor drive speed)

PID Control process variable (PV) & setpoints (SP) in eng. units
i.e. automatic regulatory control based upon the PID control algorithm:
Feedback only (SISO . Single input, single output)
Feedforward and Feedback (MIMO, Multiple input, multiple output)
Ratio Control and Cascade Control
Split Range Control
Smith Predictor . dealing with significant time delay
MPC (Multivariable Predictive Control) or Model Based Control based on
true process dynamics, and using recent history & a model based trajectory
Rule or Fuzzy Control based on knowledge / experience
Automation Control of:
specific known actions or sequences; batch processes; etc.
Advanced (Optimizing) Process Control
Simplest of Controllers

we all know!

Dual Zone Controller:

AUTO (or Man)
SPs, Frost Warning,
& Outside Temp

Note: No Measurement
Shown!

Note: No Setpoint or Measurement Shown!

SAG Mill Under Manual Control
Bartsch, Mill Load &
CMP 2008 Power
INCREASING
Multivariable issues: But note, rich feedforward D75 size information:
Plot-0 Bearing Pressure
200 2500 4500 0.085 PRI-21WIC0204.SP
Mill Load & 130.00000
180 Mtph
Power PRI-21ML01.AV
2163.43750
160 DECREASING kW
PRI-21PIT0457C.AV
Mill Power 4363.49463
140
Feed rate, fixed at 130 tph kPa
PRI-21VT28.D75.AVG
120
Mill Feed Set-point 0.04566
m

100 Large size

fraction (D75)
80
DECREASING
D75 Size Fraction
60
Large size
40 fraction (D75)
INCREASING
20

0 1600 0 0.035
9/29/2002 9:30:00 AM 12.00 Hour(s) 9/29/2002 9:30:00 PM
TONNAGE ALIM.BROYEUR AUTOG
PUISSANCE BROYEUR AUTOGENE
PRESS. D'HUILE PALIER DECH
Alimentation Moulin AG D75
How is Control Applied?
(in our industry)

predominantly simple, regulatory control

Mines
Ventilation air flow (and pressure) control, compressed air and dewatering controls
Milling
Feed and Tonnage control, water ratio control
Pumpbox and surge tank controls
Cyclone pressure & density controls
Flotation, pH, air flow & level controls. for Grade / Recovery Control
Reagent (chemical controls) & ratio controls . for Grade / Recovery
Thickener bed level, flocculant, density, for clear overflows and final moisture controls
Roasting / Smelting
Feed controls . of all feed materials (concentrates, fluxes, etc.)
Air flow, pressure and temperature controls
Power controls . ideally as a ratio to feed rate
Duct pressure, fans, blower and acid strength, reagent & quality controls
Inventory controls
Refining
Purification, electrolysis, chemical and electroplating, stripping, packaging controls, etc. etc.
Layering of Process Control

General Process Control Hierarchy

Objective Function
Cash Optimization
Site
Economics
Plant Plant
Optimization
Optimization
Advanced
Process
Optimize
Optimizing Control

Stabilize Loop Control

Regulatory
Field / Panel / DCS / PLC
Measure
Instrumentation - Inputs / Outputs Manual
Economic
Return Processes
Leveraging Control Technology
BBA Inc. (M.Ruel)

or Control
Impacts
Business
Profitability
($$)

18
Advanced Process Control (APC)
Hydro Management &
Site Peak Power Control

Economic Benefits of Supervisory Process Control at Kidd Creek

Dec. 1993 Noranda Technology Conference, by P. Thwaites, J. Carriere

Hydro Management & Site Peak Control Objectives:

Improve knowledge & awareness of power costs
Improve & stabilize SITE power control (at approx. 133 MW of power consumption)
Control the daily Peak load and shift power consumption to Off Peak while maintaining production
Using 3 zinc plating rectifiers at approx. 22 MW maximum power each

Results:
1. Lowest overall (c/kWh) Ontario Hydro Mining customer using TOU (time of
use) Hydro rates
2. Cumulative (5 year) total savings from 1989 to 1993 incl. = $17,600,000
1. 1989 = $2.0M saving on 1,089,851 MWh
2. 1990 = $2.4M
3. 1991 = $3.5M
4. 1992 = $5.6M
5. 1993 = $4.1M saving on 1,076,755 MWh

Conclusions:
1. There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control

APC, can have considerable returns

. to help the Business!
Importance of Control Performance

EMERSON Global Users Exchange (2007)

Diagnostics . are
you using them?
5 Essential Control Loop Elements (D. Harrold)
& Consider the Whole Loop (Forsman ABB)

Five Essential*
Control Loop Elements: Consider the whole loop
PC-program in 3
1. Sensing element Advant OCS
2. Transmitter Ramp rate Filter
3. Controller
Deadband
4. Final Control Element D/A
(e.g. Actuator or VSD) 4-20 mA A/D
4-20 mA
I/P
5. Process 3-15 psi
Filter
mV
Positioner Filter
0-6 bar

Only when all five elements Actuator 4 2 FT

are performing at their best 5. Process
will the control system meet
expectations!
ABB Corporate Research
K. Forsman, 1998, No. 10
1 ABB
* February 1999 CONTROL ENGINEERING
by Dave Harrold.
Importance of Regulatory Loop Tuning
(Flotation air flow loop)
Retuned, Old to New
Poor to Improved, prior to Optimized
Process Control Improvements - Primary
Grinding Circuit
regulatory control

Primary Feed Tonnage

20%
STD=14 t/ h
With proper filtering & 18%
STD=50 t/ h
tuning 16%

14%

Frequency (% )
12%

Standard Dev: 10%

72 % reduction of
standard variation
BEFORE
AFTER

50 14 t/h 8%

6%

4%

Reduction: 72% 2%

0%

30
0

0
5

15

45

60

75

90
-9

-7

-6

-4

-3

-1
0
-1

Bins - Feed Rate Set-Point Deviation

Note, we normally ratio Mill water to feedrate!

Process Control Improvements - Primary
Grinding Circuit
regulatory control

Mill Discharge Water Addition

20.0%
Benefits rougher feed density 18.0%
STD=0.007

STD=0.017
16.0%

14.0%

Standard Dev:
Frequency
12.0%
BEFORE
10.0% 58% reduction of
0.0170.007 kg/l 8.0%
standard deviation AFTER

6.0%

4.0%

Reduction: 58% 2.0%

0.0%

03
3

01

02

04

05
0
5

1
.0
.0

.0

.0

.0

0.
0.

0.

0.

0.
-0
-0

-0

-0

-0
Bins - Primary Rougher Feed Density Set-Point Deviation
Eland Mill (2010) Overall Recovery Improvement from:
Primary Grind & Primary Rougher Recovery Improvements

55 On a feed grade of
1) Prim. Grind Improvement: 2.54 g/t PGE:
50
Before:
45
42% -75microns Before Sec. rougher
40 After tails dropped
After: 0.24 g/t;
35
52% -75microns
30 Before After Overall plant
2) Primary Rougher rec. increased
Recovery Improvement: 75 3%;
70
Before: 65

60% 60 Final
55 Before concentrate
After: 50 After grade increased
45
73% 40 by 10 g/t.
35
30
Before After
Control Loop Improvement
(Flotation level controller)
regulatory control, bias removal

Reduction: 56% &

Bias Elimination
25.0%
Several loops were updated. 56% Reduction of STD deviation
100% Reduction of average deviation
STD DEV: 2.7%

20.0%

Typical results: Bias elimination

Reduction of variability
Frequency
15.0%
BEFORE
Elimination of bias STD DEV: 6.0%
AFTER
10.0%
virtual absence of Integral
action
5.0%
Smoother control action
KPIs (key performance 0.0%

indicators) at target -30% -25% -20% -15% -10% -5% 0% 5%

Bins - 106B Level Set-Point Deviations (LIC-3506)

Flotation Cell Level Control

Control Tuning Summary
Dont underestimate the impact!

Proper controller tuning is the largest, quickest, and least

expensive improvement one can make in the basic
control system to decrease process variability.
T.L. Blevins, G.K. McMillan, W.K. Wojsznis, M.W. Brown, Advanced Control Unleashed, ISA
Press, Research Triangle Park, NC, 2003.

------------------------------

N.B. Book was inspired by DeltaV

Advanced Control Products.
Available from ISA or may be ordered at
EasyDeltaV.com/Bookstore
Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Discussion topics include:

Control Engineering, as applied to Process Control:
Process Variability, Control & Process Optimization
Control Solutions from Manual control & operation
Control Loop, Applications & Tuning Impacts
The Technology, Important Aspects, System Selection
Automation and Advanced Control
Elements Necessary for Success
Instrumentation Solutions .. To Be Aware of
Operational Performance Excellence:
Examples selected are: Flotation Level Control / Reagent Control
Asset and Performance Monitoring
Opportunities . for You; and for Your Plants to Consider
Automation is .
Ref. Dictionary.com

1. the technique, method or system of operating or

controlling a process by highly automatic means,
reducing human intervention to a minimum
2. a mechanical device, operated electronically,
that functions automatically, without continuous input
from an operator
3. act or process of automating
4. the state of being automated
Automation How Do We Apply It?
Ensures steps are not missed,
protects assets & improves safety

Can be done on various platforms (PLC or DCS), on specific process units

or areas of the Plant
While I am aware of fully automated, unmanned (Hydro) generation stations (turbines) where
the process is simple; we do not know of a fully automated Mill!
Recently, PYROGENESIS (GH) reported on their Plasma Arc Waste Destruction System for
the US Navy Carrier, Marine vessels & mobile units a fully automated process.
Some Automation examples we see:
Motor starts and stops e.g. crushing plants; and sump pump controls
Remote starts, start-up and shutdown sequences, can be quite complex!
Mill lube systems; Conveyor belt material handling systems
Mine Drilling equipment and (Mine) Autonomous haulage:
Vale puts Railveyor to test Sudbury Mining Solutions Journal, Sept. 1st, 2012
A key pillar of Rios mine automation initiative is autonomous (vehicle) haulage -
Technology Case Study: Rio Tinto, Mining, People & the Environment, Jan. 2012
Pressure filtration & Batch processes;
Automated metal (plate) stripping, as we use for Ni, Cu & Zn stripping.
. etc. etc.
Advanced Process Control (APC)

In terms of automation functionality, regulatory control & APC serve much different purposes.

The primary role of regulatory control is to ensure stable, safe, and reliable
operations while maintaining process units at a desired or specified condition.
It does not attempt to continuously improve operations in an economically optimal manner.

APC, on the other hand, is a supervisory control application that coordinates a large
number of parameters to maintain control closer to operating constraints and more
favorable economic operating conditions.

E.g.
Roaster Control Layered, MPC (Model Based Control, with optimization logic), on
top of well tuned PID mass feed controllers.
Results:
1. 77% reduction in bed temperature Stnd. Dev allowing temperature and
throughput optimization, closer to Roaster constraints.
2. Overall throughput increase over extended periods of 4%.
DeltaV (Emerson) Systematic Approach

DeltaV APC blocks are Drag-n-Drop and

Embedded in controllers, not in a separate system

Advanced Control
Fuzzy Logic
Neural
MPC (Model Predictive Control)
Predict / PredictPro
The Collahuasi Solution:
MPC ProfitSAG replaces Expert Systems (Rules)
(CMP 2010 Presentation from Ivn Yutronic (CMDIC),
Rodrigo Toro (Honeywell); see also automining2012

Honeywells ProfitSAG is an MPC solution for SAG Mills

Objective function designed to accomplish the goals (maximize
fresh feed rate)
Fault tolerant policies (anti-windup integration with regulatory
control level)
Fully integrated with measured disturbances

CVs (Controlled)
MVs (Manipulated) Mills Weight
Fresh Feed Mills Power
Mill Speed SAG Mills Noise
1011
Solids Mills Torque
Produced Pebbles

Process
DVs (Disturbance) Value Predictions

Returned pebble
Particle size
Implemented Multivariable Predictive Control
Approx 230 known MPC applications . all vendors
of these installations 70% Honeywell {B. Jonas}

MPC in Mining, All Vendors (Over 230 Units Controlled)

CrushingT
SAG/AG Mills
Ball/Rod MillsT Cu, Ni, Zi,
FlotationT Ur, Au
CCD /Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SXT
Alum. Autoclaves
FiltrationT
EvaporationT
Heat InterchangeT Alumina
Precipitation
Calciner
T=Train Kiln
Other

Note: In mining (mineral processing), excludes cement, steel

Elements Necessary for Successful
Process Control in Mineral Plants
P.T. - IFAC MMM07, Quebec City, 3rd plenary

Tools: People:
Instruments; Control / Process
Systems etc. rP ocess Knowledge
Control ->
Operational
Performance
Excellence
Actions:
Support
Successes:
Management; Results &
Technology Transfer Examples

i.e. the TEAM!

Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Discussion topics include:

Control Engineering, as applied to Process Control:
Process Variability, Control & Process Optimization
Control Solutions from Manual control & operation
Control Loop, Applications & Tuning Impacts
The Technology, Important Aspects, System Selection
Automation and Advanced Control
Elements Necessary for Success
Instrumentation Solutions .. To Be Aware of
Operational Performance Excellence:
Examples selected are: Flotation Level Control / Reagent Control
Asset and Performance Monitoring
Opportunities . for You; and for Your Plants to Consider
Mine On-Line Sampling and Analysis by
ima eng. www.ima.fi
Siemens Sensors & Communication
Comprehensive Product Portfolio for us
S. Shephard - Solutions for the Mining Industry
(Locally: Richard Simon, Chess Controls )

Process Instrumentation

Process
Flow Valve positioner protection

Level Temperature Pressure Weighing

Process Analytics Industrial

Factory Sensors
Communication

Industrial
Continuous Gas Analyzer In Situ Gas Analyzer Proximity RFID Network Industrial
Switches Systems Switches WLAN

Code Reading Fail Safe Security Communication

Kiln Sampling Probe Natural Gas Analyser (CV) Vision Sensors Sensors Products Processors PLC / PC
E+H Instrumentation for the Mining & Metals
Industry

pH best
practices
Example ?
Memosens/ Liquiline
Digital pH Systems Maximize process up- time

E+H Canada

Slide 1

Digital pH sensors with Memosens

Safe connector system

Memosens with inductive data
transmission eliminates problems
based on:
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops

Dirty connections
are irrelevent!!

E+H Canada

Slide 16

17 units = 70% savings at Minera

Los Pelambres - Chile! CPF81D + CM42
2011 Xstrata for:
Antapaccay Mill (Peru)
Las Bambas Mill (Peru)
E&H: Typical positioning of a thickener's
critical parameter measurement devices
S. Rigling E+H Australia
Flow Measurement Cidra SONAR
Ref: Christian OKeefe
cokeefe@cidra.com

SONAR A New Class of Meters with Distinct Application Advantages

Volumetric Flow Meters

Multivariable
DP

Vortex
SONAR Ultrasonic Hydrocylone feed line
as used by Collahuasi, Chile

Xstrata Cu - Standard
Concentrator (5):
Antapaccay, Las Bambas,
Coriolis (Peru) selected SONARtrac
Magmeter
for the principal slurry lines
Flow Measurement - In Circuit SONAR
Ref: Christian OKeefe, cokeefe@cidra.com
Felix, Peacock, Huysamen, Thwaites

Platinum 2012: The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator

Volumetric Flow Meter

Your accurate flow measurements are helping us with flotation control:

We have automated mass pull control across the cleaner section.
Our next phase is utilising the Level controllers, Flow Optimiser,
Analyser & Cidra meters to implement our advanced flotation control.
Buang Moloto (Eland Xstrata Alloys)
Online Mineral Particle Size Measurement
OPUS Andrew Smith, Sympatec GmbH, AUTOMINING 2010
Ultrasonic Extinction for real time
Measurement

Full particle size distribution:

from 1 micron on flows < 1.5 m/s
Camera Imaging
Portage, Metso, SGS, & Aplik (Chile)
Ore Feed, Flotation Froth,
Cathode Surfaces
- Feed size analysis;

- Froth camera imaging;

- Optical System for

cathode quality:

CSQA:
Cathode Surface
Quality Analyzer
(Aplik)
Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Discussion topics include:

Control Engineering, as applied to Process Control:
Process Variability, Control & Process Optimization
Control Solutions from Manual control & operation
Control Loop, Applications & Tuning Impacts
The Technology, Important Aspects, System Selection
Automation and Advanced Control
Elements Necessary for Success
Instrumentation Solutions .. To Be Aware of
Operational Performance Excellence:
Examples selected are: Flotation Level Control / Reagent Control
Asset and Performance Monitoring
Opportunities . for You; and for Your Plants to Consider
Flotation Objective?

One is Pulp Level .

1. Always Prevent Flooding or empty banks &

2. Maintain an Accurate, responsive Pulp Level, on a second basis,

thereby allowing control of the setpoint.

Note, pulp level is the variable known to the Operator

and is correlated to mass pull and recovery.
Flotation Level Measurement .....
Access to floats, yes important!

No access to clean floats XPSFloat

- Build up on floats Flotation level measurement
- Inaccurate reading - implement quick access to floats
- Cleaning water to rod
Flotation Level Measurement Retrofit.....
Mandalay Resources, Cerro Bayo Ag-Au Mine
Instrumentation Upgrade by E+H Chile,
(C. Aravena), & Sedgman, Chile using XPSFloats

The Cerro Bayo district is

located in southern Chile,
just inside Argentina
approx. 130 km south of
Coyhaique, the capital of
Region XI, Chile.

This district is part of an

emerging precious metals
province containing the
Cerro Bayo & El Toqui
mines in Chile, & several
mines, exploration projects
extending east - Argentina.

Ramp-up to the currently

planned 1,200 tpd ore
processing rate was
completed Qtr 4, 2012.
Flotation Level Control -
Best Practice Example

8. Best Practices
Control to Metallurgy ($$) 2. Level Control
1. Basic Level Device Tuning (PID
Flotation
Level Control Feedback)

7. Level Setpoint
Optimization 3. Split Range
(e.g. Froth Actuation
Velocity (2 Dart Valves)
Controller)
Emerson Smart
Positioners

4. Smart
6. Surge Tank Positioner
Control (Valve
Tuning 5. Level Control Tuning opening
(+ Feedforward) Feedback)
Flotation Control: Points on Control
Structure and importance of layering (Gilles)

Set Point: Use standard

ratio blocks
Operator Recovery or to ensure you
Grade Target can layer, on
top, another
Metallurgical level of control
Measurement: Control
(Tail or Conc
Assay) Set Point:
Gram/Ton

Ratio Control
Measurement:
Tonnage or
Tonnage*Head Grade Set Point:
cc/min

Flow Control

All of the Met. Loops are PI/PID controllers for supportability.

If problems occur, operators may turn off one level of control at
a time, Independently for each reagent.
 Flotation Reagent Control -
Best Practice Example
Metallurgical (Met.) Control is the goal
8. Best Practices
Flotation reagent Control
2. Specialty
=> Optimum Metallurgy ($$)
1. Basic Measurement (pure, undiluted)
+ 25% lower reagent costs
Mag meter, or Coriolis, collectors?
or pulsed device?

3. Flow Control
7. Met. Control
with feedback tuning (eng.
Optimization Units)
(Mass Pull;
Analyzer
recovery or
froth quality) 4. Ratio Control
g/Tonne

6. Met. Control
with strategies for 5. Met. Control
start-up, shutdown, (Ratio) GMU
& short stoppages,
g/Metal Unit
or losses in XRF
data Robust Reagent Control
(Feedforward only)
Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Discussion topics will include:

Control Engineering, as applied to Process Control:
Process Variability, Control & Process Optimization
Control Solutions from Manual control & operation
Control Loop, Applications & Tuning Impacts
The Technology, Some Important Aspects, System Selection
Automation and Advanced Control
Elements Necessary for Success
Instrumentation Solutions .. To Be Aware of
Operational Performance Excellence:
Examples selected are: Flotation Level Control / Reagent Control

Asset and Performance Monitoring

Opportunities . for You; and for your Plants to Consider
Process (& Plant) Monitoring
OSIsoft PI System 2010
Used extensively by Xstrata, Vale,
Anglo (South America) etc.
Measure, Control, Optimize
Flotation Control Best Practices
Sustaining the gains

Process Control

Measure Control Optimize

tim ge 3
n
tio
Process constraint

iza
Sta
higher production
units

Stabilization
setpoint

Stage 1
lower costs

Op
Flotation Control
better Stabilization
poor control control best control
to
time Optimization
7
Su
sta
ine
d Va
Sta Re riabi
ge du lity
cti
2 on
Control Performance Monitor (CPM)
{Matrikon/Honeywell} is
a control performance improvement product that
can diagnose causes of poor control at all levels of
the plant control hierarchy:

Plant Control Control Performance Monitor (CPM)

Advanced Process Control MONITORS advanced control assets for poor

performance & provides detailed diagnoses

Analyzers & Online

Inferentials
Regulatory Control
Instrumentation Layer
MONITORS regulatory control assets for poor
performance & provides detailed diagnoses
PROVIDES TOOLS detecting instrument
freezes, data spikes, rate of change alarms and
high-low limit violations

CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well as
archiving maintenance history on each loop.
 1st CPM Controller X Nis Strathcona Mill
also utilized at Raglan &
Eland Platinum Mills
Motivation:
Continuous monitoring, prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( i.e. Manual or Auto, how the controller
performs, etc. )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for:
Managers
Supervisors
Technical staff
CPM trial at Strathcona Mill

Example Case:
Persistent Strong Oscillation

Sustained Variability Reduction, CPM trial at Strathcona Mill

How we should use CPM

Xing Jin (XPS Control Engineer)

Requires
CPM
Daily
Attention
Champion Assess
Problem

PV

Weekly
Daily Time

CPM provides
assessment, notification Resolved Disposition
PV User needs to take action,
Workflow
fix the problem
Move loops with known
Time
issue to another WO
disposition category Pending
Dont be nagged on the
same problem again

Manual

Sustained Variability Reduction, CPM trial at Strathcona Mill

Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Discussion topics will include:

Control Engineering, as applied to Process Control:
Process Variability, Control & Process Optimization
Control Solutions from Manual control & operation
Control Loop, Applications & Tuning Impacts
The Technology, Some Important Aspects, System Selection
Automation and Advanced Control
Elements Necessary for Success
Instrumentation Solutions .. To Be Aware of
Operational Performance Excellence:
Examples selected are: Flotation Level Control / Reagent Control
Asset and Performance Monitoring
Opportunities . for You; and for your Plants to Consider
Perceptive Engineerings Focus / Vision
(Dr. D. Sandoz, D.J. Lovett)

Integrated Condition Monitoring

and Advanced Process Control 40

35
Soft Sensors
30

FeO
25

20

Classification for
15

10
0 20 40 60 80 100 120

Quality Control
Sample No.

Control System
Early Warning Process
40
Integration
Condition Monitors
35

30
SPE
Confidence Limit

25
SPE

20

15

10

0
0 20 40 60 80 100 120 140 160 180
Time
Kairos Mining (Chile) A Comprehensive
Approach to Sustained Benefits in Automation
CMP 2010 PAPER #27 by
Giselle Schifferli

KAIROS REMOTE SUPPORT CENTER

REMOTE MONITORING & SUPPORT CENTER

DATACENTER
TRAINING CENTER

TESTING LABORATORY
Honeywell Remote Support Centre
Kairos Mining, Santiago, Chile

Collahuasi
Xstrata Cu,
Original Focus: Codelco Casarones
AngloAmerican
-Chuquicamata
Automation deployment &
-El Teniente
support -Andina
Multiple sites supported from -Salvador
Santiago -Ministro Hales
Expanded for Asset Management: Honeywell
Provide access/network to many Kairos
service providers:
- remote servicing/configuration
Plant Eq. Monitoring
- on demand analysis & diagnostics
OEM Process Monitoring
Core Honeywell team Instrument Support
ensures success
Adding real-time expert
monitoring for
fixed equipment
Opportunities for You and Operating
Plants to consider ..
Operational Performance Excellence
requires a solid performance of the
regulatory layer AND process optimization.
For Plant Operators:
Is your feed stable?
Are your instruments 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, thickeners, roasters, furnaces, etc. etc.)
Are you using your surge capacity, . or running tight level control?
Are 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, or material consumption?
Do you Operate with or without a Control Engineer?

Does your Plant / Process or Processes run as well as your car?

We can do Much More and be Much More Efficient!

(P. Thwaites, AUTOMINING2008 Plenary lecture, Chile;
CMP 2013 Plenary lecture; CIM DL Series 2012-13)
Manual Control, Process Automation or Operational
Performance Excellence? What is the difference?

Wrap Up .

My Recommendations:
Instrumentations & Instrumentation Solutions .
Make them work for you and use more of the great instrumentation currently
available.
Control Systems .
Push your control system to keep delivering for you, reducing variability;
Use more feedforward, cascade controls & ensure controllers are tuned;
Seek input from you supplier and ensure you use what the system can do;
Automate tedious and repetitive, known tasks;
Focus on optimization and see better business performance.
Employ a Control Engineer to complement your Operations and
Instrumentation Teams.
Use Asset, Performance Monitoring tools to be more proactive.
Analyze, Act and ensure data becomes knowledge for Business
($$) actions always.
(P. Thwaites, CMP 2013 Plenary lecture; CIM DL Series 2012-13)
 Acknowledgements

Current Process Control Past Control Engineers:

1. Carol Hall
Engineers:
Acknowledgement and thanks to: 1. Alan Hyde
2.
3.
Chris Hatch
Darren Thomson
4. Dave Jakelski
Canada: A great place to work & 2. Phil Nelson 5.
6.
David Gowanlock
David Wreggett

develop, starting in 1979 - in mining! 3. Ron Bose 7. Dhruv Kak

8. Eduardo Nunez
4. Tara Rana 9. Erik Bartsch
CMP: 2013 (45th) 2nd Plenary lecture 5. Ahmed Roomy 10. Fernando Romero
11. Hayley Halsall Whitney
my 1st CMP was the 15th 1983! 6. Kabir Ahmed 12. Jeff Chenier
13. Jeremy Gillis
7. Siddhartha Kumar 14. Joachim Schubert
Atlas Copco & the Canadian Mining 15. Jocelyn Bouchard
16. John Stefanski
& Metallurgical (CMMF) Foundation 17. Joseph Hanna
All have contributed! 18. Ken Galloway

Distinguished Lecturer sponsors. 19.

20.
Kjell Stle-Hansen
Lionel Ryan
21. Martin Emond
Xstrata, Xstrata Process Support: 22. Maureen Steed
23. Martin Suiches
DF, NOL, GM, JM, my colleagues, 24. Michael Burrows
25. Michael Mosher

the +43 Process Control Engineers 26.

27.
Mike Woloschuk
Nicholas Bedard
28. Pablo Asiron
whom I have (& had) the privilege of 29. Paul Wema
30. Rene Del Villar (Jnr)
working with / leading: 31. Silvia Del Carpio
32. Thierry Bonnet
33. Titus Chen
(P. Thwaites, CIM DL Series 2012-13) 34. Victor Schweikart
35. Xing Jin
36. Zulfiqar Karim
Key Follow-up References
for Further Info & Details

Note, Out of Print!

For More on XPS
see: www.myxps.ca
& www.glencorexstrataplc.com

Thank you Come visit us

in Sudbury, Ont.
 Canadian Institute of Mines Metallurgy and Petroleum
Peru Branch ICM-Per

Jueves Minero, IIMP Lima-Peru

Manual Control, Process Automation or Operational Performance

Excellence? What is the Difference?
By Phil Thwaites
CIM Distinguished Lecturer