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CiDRA background
USA company
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CYCLONEtracSM
Optimization System for Grinding & Classification
OSM 2 versions PST
OverSize Monitoring Particle Size Tracking
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CYCLONEtrac OSM
Experience in Minera Centinela Field Data
OSM
OverSize Monitoring
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CYCLONEtrac OSM
Experience in Minera Centinela
Cu Concentrator
97 tpd, expanding to 105 ktpd
1 SAG, 2 BM,
4 batteries, 12 cyclones each
Krebs Gmax 33-inch
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CYCLONEtrac OSM, CEN
Anatomy of a severe roping event before OSM
= 9 min = 37 min
= 28 min
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CYCLONEtrac OSM, CEN
Anatomy of a severe roping event before OSM
Bat feed
density
Event start
Bat feed
flow
25 min
Power = BM load
Power
BM
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CYCLONEtrac OSM, CEN
Operators acceptance during Trial (Sept 02, 2014)
open
Alarm threshold
closed Valve open/close status
OSM signal
Month 1: operator familiarization, require visual confirmation of roping before closing cyclone.
Operator response time >> 10 min
= 3 min = 3 min
= 37 min
= 9 min = 1 min
= 1 min
= 2 min
= 1 min = 1 min
= 1 min
8 minutes
7 different cyclones rope within only 8 minutes, detected and controlled with OSM
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CYCLONEtrac OSM, CEN
Anatomy of a severe roping event before OSM
= 9 min = 37 min
= 28 min
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CYCLONEtrac PST
New Field Data from USA
PST
Particle Size Tracking
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PST - How does it work?
Probe inserted through wall of overflow pipe to
contact slurry stream
Particles strike probe, generate high-frequency
acoustic waves
Electronics captures acoustic signals and
produces frequency spectrum
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CYCLONEtrac PST
Ex: Effect of single poorly performing cyclone
SABC circuit
(2 bat x 14 cy/bat)
(2)
(1)
(1)
Assumptions:
Steady-state (constant circulating load): SAG throughput = Flotation Feed
...while average
particle size
decreases because...
OF
UF
circ load
feed density
BM power (kW)
Cyclone classification
(could trick Virtual
Particle Size Sensor!)
BM unloads (P increases)
More process instability!
Effect on BM
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CYCLONEtrac PST - Effect of single poorly performing cyclone
Effect on particle size
PST particle size (% + 150um)
Produces...
~+1,000 t/h
Effect on cyclone feed mass flow Above steady state rate!
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CYCLONEtrac PST- New Field Data from USA
Overall Optimization Benefits
PST
Particle Size Tracking
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Controlling Grind Size is Critical
As throughput increases,
particle size increases
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Sustainable Grind Circuit Control
Requires Particle Size Measurement
Real time
Provide 100% availability
Full stream analysis
Low Maintenance
Reliable and repeatable
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Grind Circuit Control Strategies
Particle size based on a
sampled flotation stream
Estimated grind sized based on processed through the lab
the incoming ore, historical - turnaround time not
performance, and plant adequate for real time
conditions control
OR
Consolidated cyclone
overflow sampled and
processed through a PSA
or PSM with poor
Control Strategies that rely on availability
indirect measurement, i.e.:
OR
Hydrocyclone model
Quick wet sieve grab
Virtual sensors samples not suitable for
Cyclone
real-time control
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Control Development with PST
identify parameters highly correlated with particle size
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Grind control using CYCLONEtrac PST - implementation
Agua
Control del
Control del Control de
Molino % +150um
% Slidos la Presin
SAG
PST
Control del
Molino
Bolas P
Cicln
%Slidos
P+I P+I
% +150um + Control + Control
Set Point del Agua
del % de
- %+150 - Slidos
PST
Plant wide control adoption
4 months to full-plant >80% availbility
Utilization
Time
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Testing multiple constraint control
can drive process to particle size set point range
PST
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Results
Final plant control strategy is NOT to hold a constant particle size
product from the cyclones but to keep within an acceptable
range (20 to 35 percent above 150 micron).
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Results BM1: Particle Size vs Throughput
R2 = 0.39
R2 = 0.44
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Results BM4: Particle Size vs Throughput
4.5% +150um size reduction at same throughput
R2 = 0.45
R2 = 0.15
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Results
BM1: Particle Size vs Specific Energy
R2 = 0.15
R2 = 0.45
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PST Conclusions
implemented a new control strategy in the ball mill circuit using
new PST particle size measurement technology.
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Thank You
Chile Representative
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