Title

STATIC AND DYNAMIC SIMULATION FOR THE DESIGN OF ADVANCED PROCESS CONTROL SYSTEMS IN MINERAL PROCESSING

APPLICATION OF STATIC AND DYNAMIC SIMULATION TECHNOLOGIES FOR THE CONFIGURATION OF ADVANCED PROCESS CONTROL SYSTEMS IN THE MINERAL INDUSTRY

Authorship

MARTINS, MARCO AURÉLIO SOARES; GODOY, VALENTE OBARA; FERREIRA, KELLY CRISTINA; SOUZA, EDWIN WILKER CHAVES

MARTINS, MARCO AURÉLIO SOARES

I am this author

GODOY, VALENTE OBARA

I am this author

FERREIRA, KELLY CRISTINA

I am this author

SOUZA, EDWIN WILKER CHAVES

I am this author

DOI

10.5151/2594-357X-42511

Downloads

Abstract

This paper presents an innovative methodology for the early development of Advanced Process Control (APC) systems in the mineral industry, based on the integration of dynamic simulation, static simulation, and model-based control. Proprietary tools developed by CEMI and static models calibrated using USIMPAC, are used. This approach allows for the early configuration of APC systems with a high degree of realism, even in greenfield projects still under construction. The methodology enables full simulation of unit operations and equipment such as conveyors, pumps, and kilns, incorporating operational know-how from the early design phases. As a result, it provides greater predictability, reduced commissioning time, direct support for startup and ramp-up, and technical standardization of delivered solutions. Two case studies are presented: one focused on the beneficiation of itabirite ores through comminution and flotation, and another on the pelletizing process and thermal hardening.

THIS PAPER PRESENTS AN INNOVATIVE METHODOLOGY FOR THE EARLY DEVELOPMENT OF ADVANCED PROCESS CONTROL (APC) SYSTEMS IN THE MINERAL INDUSTRY, BASED ON THE INTEGRATION OF DYNAMIC SIMULATION, STATIC SIMULATION, AND MODEL-BASED CONTROL. PROPRIETARY TOOLS DEVELOPED BY CEMI AND STATIC MODELS CALIBRATED USING USIMPAC, ARE USED. THIS APPROACH ALLOWS FOR THE EARLY CONFIGURATION OF APC SYSTEMS WITH A HIGH DEGREE OF REALISM, EVEN IN GREENFIELD PROJECTS STILL UNDER CONSTRUCTION. THE METHODOLOGY ENABLES FULL SIMULATION OF UNIT OPERATIONS AND EQUIPMENT SUCH AS CONVEYORS, PUMPS, AND KILNS, INCORPORATING OPERATIONAL KNOW-HOW FROM THE EARLY DESIGN PHASES. AS A RESULT, IT PROVIDES GREATER PREDICTABILITY, REDUCED COMMISSIONING TIME, DIRECT SUPPORT FOR STARTUP AND RAMP-UP, AND TECHNICAL STANDARDIZATION OF DELIVERED SOLUTIONS. TWO CASE STUDIES ARE PRESENTED: ONE FOCUSED ON THE BENEFICIATION OF ITABIRITE ORES THROUGH COMMINUTION AND FLOTATION, AND ANOTHER ON THE PELLETIZING PROCESS AND THERMAL HARDENING.

Keywords

Advanced Process Control (APC) – OptProcess, Dynamic Simulation – OptSim, Static Simulation – USIMPA

Advanced Process Control (APC) – OptProcess, Dynamic Simulation – OptSim, Static Simulation – USIMPAC, Process Modeling