MODELLING,PROCESS CONTROL

SIMULATION & SAMPLING

Ref BA Wills pg 39-86
7th Edition
 Objectives
To know the importance of process control,
modelling and simulation in mineral process
engineering.
To know the role of sampling in metallurgical
accounting practice.
 Lecture content
Metallurgist role in process engineering
Computer simulation
Process control
Types of models
Pros and cons of computer simulation
Sampling
 Why control?
To enable process variables to be kept or
maintained at a predetermined level to
enhance process efficiencies.
To allow for troubleshooting within plant
operations.
 Role of metallurgist
Design

Process optimization

Cost control
 Computer simulation
Powerful tool in plant design and process
optimization
Accurate prediction of process
performance necessary
Objective to reduce the inherent high
capital and operating costs.
Relate performance to costs
 How?
Use of simulation techniques
Techniques rely on various mathematical
models
Use of design software
PROCESS CONTROL
 Function of process control

Ulsoy and Sastry (1981):

Function is to stabilize the process
performance at a desired level, how?
By preventing or compensating for
disturbances to the system.
 Objectives
Stabilization of process performance
Optimization of process performance
based on economic considerations
(Mular, 1979a)
 How?
Development of process instrumentation
systems
Manual systems and automatic control
systems.
Use of P, PD, PI and PID controlled systems.
Example SCADA
P= proportional, PD = proportional
derivative, PI= Proportional integral, PID =
Proportional integral derivative
 Statistical process control
Methodology involving simple graphical
techniques : Example
Control charts
Cumulative sum (cumusum) charts to plot
process data as a time series.
Together this data assessed with statistical methods
to determine whether process is out of control as
governed by some performance criterion, ie low
recovery, concentrate grade etc( Ipek et al..,1999)
 Benefits
Analysis of historical data
Decision making
MODELS
 What is a model?

An equation, set of equations relating

responses( independent variables) of
interest to controllable independent
variables.
 Types of models
Theoretical
Empirical
Phenomenological
 Theoretical
Developed from basic scientific principles
Necessitate sound understanding of
process.
Rarely applicable to mineral processing
due to complexities of physico-chemical
processes involved.
 Empirical
Simplest of all
Generated from empirical process data
Less expensive than theoretical
Because the later requires first principles
and much experimentation (Mular, 1989)
Characteristics of empirical models
Express process performance in terms of
process variables
By use of simple linear regression methods
Validity- only for that particular process and
within operating limits of data collected
Example of empirical model is the partition
curve, used to assess efficiency of
classification and separation processes.
 Use of empirical models
Development leads to a better
understanding of the process.
Can help production of more general
models.
Models can be produced easily and
cheaply.
 Phenomenological models
Hybrid models
That is a combination of theoretical with
empirical
Developed from mechanistic process
description in conjunction with physically
meaningful process parameters determined
from experiments as opposed to abstract
basic science. (Sastry, Lofftus, 1989; Sastry
1990)
 Example

Population balance approach applicable

in simulating communition processes.
 Characteristics of Phenomenological
models
More realistic representations of process
than empirical.
Can be extrapolated.
Effectiveness extended by correlation of
calculated parameter values and process
operational variables.
 Mathematical models
Dynamic

Steady state

FOR FURTHER READING

 ADVANTAGES OF COMPUTER
SIMULATION
Provide accurate predictions of
metallurgical circuit alternatives
Used for design optimization
Compute process streams flow rates for
sizing pumps, pipelines etc. in
PFDs(Process Flow Diagrams) and
PIDs(Process& Instrumentation
Diagrams)
Above allows tedious and expensive
CONS OF COMPUTER SIMULATION
Necessary to take into account the
realistic operating range over which the
models are used.
As well as realistic limits on which
equipment operation must be placed
such as pumping capacity.
 CONCLUSION
Simulation studies- powerful and useful
tool
Complement sound metallurgical
judgement & familiarity with circuit being
simulated & its metallurgical objectives.
 Sampling

Importance of sampling
Role in metallurgical accounting
Types of sampling methods
Machinery used in sampling
Sampling errors