Title

OPTIMIZATION OF CRUSHING OPERATIONS THROUGH ADVANCED PROCESS CONTROL: A CASE STUDY

OPTIMIZATION OF CRUSHING OPERATIONS THROUGH ADVANCED PROCESS CONTROL: A CASE STUDY

Authorship

NUÑEZ, FRANCO NICOLAS BERRIOS; MANRIQUEZ, MARCO ANDRES ENCINA

NUÑEZ, FRANCO NICOLAS BERRIOS

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MANRIQUEZ, MARCO ANDRES ENCINA

I am this author

DOI

10.5151/2594-5335-40949

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Abstract

IN THIS WORK, WE PRESENT THE CONTROL PHILOSOPHY AND RESULTS OF THE IMPLEMENTATION OF AN INTEGRATED MPC STRATEGY USING HONEYWELL APC IN A CRUSHING CIRCUIT. THE STRATEGY IS BASED ON THE DEVELOPMENT OF UNIT APC PROCESS CONTROLLER APPLICATIONS FOR EACH UNIT PROCESS AND ITS COORDINATION WITH A GLOBAL OPTIMIZER USING APC MULTI-UNIT OPTIMIZER. ADDITIONALLY, WE HAVE IMPLEMENTED A TRIPPER CAR DYNAMIC MODEL IN PYTHON, WHICH PROVIDES EXTERNAL KNOWLEDGE OF THE FUTURE BEHAVIOR OF THE TRIPPER CAR, THEREBY IMPROVING PREDICTIONS OF CONTROLLED PROCESS VARIABLES. BY ACKNOWLEDGING THE MULTIVARIABLE NATURE OF THE PLANT, THE APC SOLUTION CAN MANAGE SEVERAL OBJECTIVES AND CONSTRAINTS USING THE FEEDER SPEEDS OF THE CRUSHING AND SCREENING STAGES. THE INTEGRATED APC SOLUTION HAS SHOWN POSITIVE RESULTS FOR THE PLANT, WITH AN AVERAGE PRODUCT INCREASE TO AGGLOMERATION OF 3.49% AND A REDUCTION IN VARIABILITY OF 23.53%.

IN THIS WORK, WE PRESENT THE CONTROL PHILOSOPHY AND RESULTS OF THE IMPLEMENTATION OF AN INTEGRATED MPC STRATEGY USING HONEYWELL APC IN A CRUSHING CIRCUIT. THE STRATEGY IS BASED ON THE DEVELOPMENT OF UNIT APC PROCESS CONTROLLER APPLICATIONS FOR EACH UNIT PROCESS AND ITS COORDINATION WITH A GLOBAL OPTIMIZER USING APC MULTI-UNIT OPTIMIZER. ADDITIONALLY, WE HAVE IMPLEMENTED A TRIPPER CAR DYNAMIC MODEL IN PYTHON, WHICH PROVIDES EXTERNAL KNOWLEDGE OF THE FUTURE BEHAVIOR OF THE TRIPPER CAR, THEREBY IMPROVING PREDICTIONS OF CONTROLLED PROCESS VARIABLES. BY ACKNOWLEDGING THE MULTIVARIABLE NATURE OF THE PLANT, THE APC SOLUTION CAN MANAGE SEVERAL OBJECTIVES AND CONSTRAINTS USING THE FEEDER SPEEDS OF THE CRUSHING AND SCREENING STAGES. THE INTEGRATED APC SOLUTION HAS SHOWN POSITIVE RESULTS FOR THE PLANT, WITH AN AVERAGE PRODUCT INCREASE TO AGGLOMERATION OF 3.49% AND A REDUCTION IN VARIABILITY OF 23.53%.

Keywords

Crushing; Control; APC; Optimization

Crushing; Control; APC; Optimization