ProfitController

Grinding Optimisation
磨矿优化技术
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Agenda目录
• Benefits效益
• Grinding Control磨矿控制
– Traditional传统
– Profit Grind智能磨矿
• Project Implementation项目实施流程
• Payback投资回报
• Conclusion总结

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Typical Benefits典型效益
• 2% throughput increase处理量增加
• 0.5% recovery increase回收率增加
• 4% power saving（ plus carbon credits ）
节电（增加碳信用额度）

效益 > $1M/年
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Grinding Circuit Objectives磨矿回路目标

• Reduce ore size to liberate valuable minerals whilst通过降低矿石
细度增加有用矿物资源同时：
– Maximising throughput最大化处理量
– Minimising power降低能耗
– Minimising water addition减少用水量
– Minimising operational moves降低劳动强度

• Disturbances干扰因素
– Feed size variations进料大小变化
– Ore hardness variations矿石硬度变化
– Weather天气

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Mill Control Problems磨矿控制存在的问题

• Long Delay Times长滞后

• Process Interactions过程的强耦合
• Material type changes矿石类型变化
– Hard, Soft, Viscous, Talcy, Coarse, Fine etc.软硬度、粘度、滑石
含量、粗糙度和细密度等
• Pinion Stress, Mill Damage
齿轮压力，磨机损耗
• Power Excursions (SAG, AG)
供电波动
Power

Ore Type
• Mill Spills (SAG, AG, Ball)
磨机溢流
• Product Size Distribution
产品粒度分布
Load
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Typical Grinding Circuit典型磨矿回路

Product
PSM
PT
Cyclone

Water

PID SP Water DT

FT FT
PID SP
New Feed Mill FT

SPEED WT WT NT JT

PID LT

SP SP PID SPEED

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Regulatory Control Difficulties常规控制的难点

• Feedback Only只有反馈控制
• Steady State Only
• Constraint Handling约束处理
• Tuning参数调整
• Optimisation优化
Operations – Regulatory Control

Sub Optimal Control控制 – Heavily Operator Dependent

过程优化 – 取决于高强度的操作
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ProfitController
Economics and Ideal
Target Values
• Profit Controller – Model-Based Control基 效益因子和理想目标值
于模型的控制
• Built-in Local Optimization嵌入式的局部优 Product Value
化 Control
Optimization Disturbance
Variables Values
– linear and/or quadratic objective function线性和 被控变量 RMPCT 干扰变量
二次目标函数 Algorithm
– Optimization speed tuning parameter优化速度
调节参数
– MV/CV economic values MV/CV效益因子 Manipulated
Variables
– Accepts ideal target values from outside 操作变量
applications可以从外部获取理想目标值
– Constrained optimization约束最优化
• “One-knob” tuning 一键调整 Past Future
• Dynamic state estimation capability Optimal Response

动态估计能力 Setpoint Predicted

Predicted
CV Unforced
Unforced
• On-the-fly gain updating随时增益矫正 Response
Response
Control Funnel

MV Assumed Values

Minimum Effort Move

T=0
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Elements of Profit Controller原理

Ore Characteristics
• Model based control RMPCT
Op tim ize r
S m a rt Mo du le s
基于模型的控制
Grin din g
• Future prediction CV, MV
History
P re d iction Co n trolle r OP s Mill P Vs

Neural Network
模型预测 Throughput Mod e l

• Constraint handling Optimizer

约束处理 O
Feedratee
Mill Water U
T
Sump Water P
Sump Pump Speed U
COST $ $ $ $ T
Cyclone $ S
I O/F Size
N Mill $
P Power Model
U Circulatin $ Predictive
T Load
Economic
S $ Optimum
Mill
Weight
Time to Steady State
Dynamic Matrix

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Profit Grinding Control智能磨矿控制

Controlled Profit Grind
Variables
PSM
Controller
Product
PT
Manipulated
Cyclone Variables

Water

PID SP DT
Water
FT FT

Mill PID SP
New Feed
FT

SPEED WT WT NT JT

PID LT

SP SP PID SPEED

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MPC Benefits多变量控制的效益
• Process stabilisation Specification
or Limit

过程平稳
• Reduce energy节能 Average
 Average

• Increased throughput增加产量
• Reduced problems减少潜在问题 Current Variations Move Average
Operation Reduced Closer to
Profit Controller Operations With APC Specifications or Limit

Ability to operate close to real process limits

可以实现真正的卡边操作
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Implementation Methodology
• Kick off – design review开工会-设计评审
• Project Design –seed matrix design项目设计-种子模型的开发
• System Install系统安装
– Profit Server服务器 Model Self Identifies模型自辨识
– Profit Stepper智能测试
• Commissioning试运行
– Model fine tuning
模型微调
– Operator Training
操作员培训
– Site Acceptance Testing
现场验收测试

Overall Project < 6 months

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Conclusions总结
• Grinding is a key process step磨矿是关键工序
– High power user大功耗
– Throughput limiting处理量有限
– Critical for downstream recovery对下游的回收率至关重要
• Regulatory control has limitations常规控制的局限性
– Generally de-tuned
– Sub optimal control次优控制
• ProfitController for grinding optimises control 针对磨矿回路
ProfitController的优化控制
– Optimise for profit效益优化
– Reduce costs降低成本
– Improves existing control system提升现有控制系统

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