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AggFlow Training Session
Charlotte, North Carolina
February 18-19, 2009
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Day 1 - Agenda
09:45 Break
12:00 Lunch
13:00 In Depth
Crushers; Database Assumptions; Interpolation of Gradations, Calculation Methods
Screens: Database Assumptions, Calculation Methods, Screen Area Efficiencies
Running The Plant; Red Flags, Maximizing Plant Flows, Applying Specifications
Reports, Graphs, Using Color & Making Notes on Worksheets
Sample Problems & Exercises
14:45 Break
Day 2 - Agenda
10:45 Break
11:00 Measurements
Sample Buckets, Belt Scales, Measuring Flow Rates & Gradations
Measuring Crushers, Screens, Stock Piles and Validating Calculations in Plant Data
Sample Problems & Exercises
12:30 Lunch
14:30 Departure
Conduct “What-If?”
Selecting & Adjusting Specific Equipment
Scenarios
Switch to Different
Apply Monitors To See Results Operating Modes
Instantly
Fine-Tune Equipment
Your Best Resource: Select Help, then Open Manual Operation
Identify Plant
Simple Plant Setup Inefficiencies &
Bottlenecks
Example #1: Setup and Experiment a Simple Plant
Reduce Calculation Time
Improve Fuel
Consumption &
Emissions
Customize Plant
Calculations and Reports
Introduction To AggFlow
AggFlow History
Story of the thumb that controlled profitability
Continuous development since 1993
Currently employed in 63 countries
Installed on your computer is the latest version of AggFlow (200811)
Includes Water Mass Balance Calculations & French/Spanish Translation
OUR GOAL: Tomorrow Afternoon You Will Be Highly Proficient Using AggFlow
Make AggFlow your plant process benchmark
Layout any type of plant
Identify and resolve bottlenecks
Make AggFlow accurate for your plant
Know what questions to ask to improve overall efficiency
Produce plant files, equipment and production reports & graphs
Optimize Plant Production and Maximize Profitability
What AggFlow Is & What AggFlow Is Not: How To Use This Tool
Benchmark
Extremely Sophisticated Calculation Tool (Aggregate : Water)
AggFlow is not artificial intelligence – It does not think for itself
User Interface
Zoom features
Multiple selections using shift key
Copy/paste blocks
Graphical Undo
AggFlow Tricks
Multiple windows can be open at once
Read the bottom panel for information!
Always keep your program updated
Use your best resource – Open the manual!
Crushers
Model Selection
Manufacturer limits
Book gradations
Interpolation of Gradations
Calculation Method
You are in complete control of the output gradations. AggFlow does not calculate automatically.
AggFlow does not calculate an output gradation based on changes to input gradations
You must specify the output gradation by adjusting the equipment set-up in the program
AggFlow actually ignores the input gradation and relies completely on your output specifications
AggFlow does pay attention to the incoming flow rate and ensures mass balance
Crushers (continued)
Common Mistakes
Modeling mistakes
Not sized correctly
Not set correctly
Operational mistakes
Not maintained
Not fed correctly (Crushers & Screens)
Not loaded near capacity
Book crusher data not correct for equipment application
Screens
Model Selection
Adjust as needed
Add new size to database
Calculation Methods
VSMA
Open VSMA sheets
Cedarapids
Deister
Scalper calculation
DBD discussion & efficiency
Screens (continued)
Common Mistakes
Modeling mistakes
Not sized correctly
Equipment not set-up correctly
Other constraints; conveyors, chutes and feeders
Misapplication of equipment
Operational Mistakes
Equipment is not maintained
Screen is not fed correctly
Screen operating parameters
Wrong media
Wrong flow direction
Water amounts
No correction for screen operational parameters
Under loaded screens
Example #6: Under Loaded Screen
Red Flags
Note: AggFlow highlights problem areas and equipment exceeding warning levels by turning the
equipment in the worksheet red. However, the program will continue to perform calculations as if there
was no problem. Therefore, you can choose to address, or ignore, red flags at anytime.
Warning Levels
Three warning levels:
Alarms; AggFlow alerts you when calculated results may not match field results
Warnings; Items to be aware of, will not likely affect calculations or results
Missing Limits; Manufacturers have not supplied crusher limits and AggFlow has no limits here
Example #7: Warning Levels
Apply Specifications
Product Mix
Saving Settings
Save multiple files (unlimited)
AggFlow View Results defaults to last view saved
Automatic Save (set time period in User Preferences)
File Recapture – in a system crash, AggFlow will provide the option to recapture/save unsaved files
PDF Reports
Worksheet and results
Spreadsheet Reports
Provides complete report and equipment list in spreadsheet format
You can select individual or a selection of line items (hold the SHIFT key)
Advanced Features
Apply Specifications
Specification database
Example #8: Goal - Figure out how to get sample to meet spec
Modes
Modes allow unlimited number of plant setups within each plant file
Example #9: Goal 1 – Use Modes to optimize the same plant for two different products
Example #10: Goal 2 – Use Modes to add a splitter and a new crusher to an existing plant
Blending
Simple Blend Demo
Linear programming info
Example #11: Goal – Determine how many products this plant can make
Dust Calculations
Example #12: Simple Dust Example
Conveyors
Calculation methods
Example #13: Simple Conveyor Example
Monitor “Layers”
Example #15: Monitors - Create a TPH and a Settings Monitor Layer
Import/Export to Excel
Example #16: Export AggFlow data to Excel, change it, Import the data back to AggFlow
Internet Features
Get Automatic Updates (regularly!)
Send emails & plant files from within program
Automatic error reporting
Send plant files directly to AggFlow Team for review/help
Send support requests and suggestions to AggFlow Team from within program
Create PDF, JPEG and TIFF files
Day 1 Review
Crusher Selection
Database assumptions; Model selection; Reduction ratios; Calculation methods; Common modeling
and operational mistakes.
Screens
Database assumptions; Model Selection; Calculation methods; Screen area calculations &
efficiencies; Calculation methods; Common modeling and operational mistakes.
Advanced Features
Applying specifications; Modes; Blending: Dust calculations; Conveyors; Multi-page Plants; Monitor
Layers; Importing/exporting to Excel; Internet Features.
Wash Equipment
Sand Screw
Basic operation and AggFlow simulation
Classifying Tank
Measurements
Sample Buckets
Quality Control Samples plugged in the flow calculations
Example #19: Install Sample Buckets
Example #20: Demo Excel Interface
Belt Scales
Example #21: Install Belt Scales
Flow Rate
Typical Flow
Primary in-feed not measured
Optimum Flow
Detailed gradation below 4 to 7 inches
% of oversize material
Crushers
Typical
None
Optimum
Input gradation
Output gradation
Measurements (continued)
Screens
Typical
None
Optimum
Output gradations
Stock Piles
Typical
Gradations
Optimum
Gradations and rates
Calculation Levels
Level 1
Setup with generic data
If you have average material with standard compression crushers this gets you to level 2
If you have impact crushers you may or may not get to level 2
Data varies greatly from one manufacturer to the next
You may need crusher samples to get past this point
Results may be off - but experts report that incremental change is usually very good
Level 2
Take plant measurements to verify results
May identify problems
Experienced aggregate manager uses this model to identify improvements and problems
Level 3
You have enough data to totally optimize production with accurate results
You reach a point where "what if" calculations are consistently accurate and reliable. Use your
experience to estimate where that point is.
Establish Benchmark
Example #23: Sample Plant File
Example #24: Determine Bottlenecks
Screens
Monitor efficiency
Size adequate?
Change mesh openings
Lower rate
Crushers
Try to maintain design capacity
Example #25: Sample File Reviews
Example #26: Evaluate Sample for Accuracy