minerals processing solutions automation · and software (metso dna or any other dcs or plc based...

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Minerals Processing Solutions

AutomationGet the most out of your mineral processing plant

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Metso process automation know-how means productivity improvement

PCD – Process Control Diagram Establish the base, motor control, the right instruments and sensors for your process.

DCS – Distributed control system – centralized informationDesign and implementation of the control strategy, where process and technology gets integrated.

Our process knowledge is the foundation of your automationMetso is the global leader in minerals processing solutions. Our expertise is based on over a century of experience, and today’s industry-leading solutions embrace the latest technology.

Metso technology is made up of a global pool of highly dedicated people who work closely with all parts of Metso Mining and Construction products and services, giving it a unique position in the industry.

Our long experience in getting the most out of mineral processing plants

”We are experts in automation and minerals processing technology.

And above all, we are experts in integrating automation systems for the mining industry”.

From instruments to advanced control systems

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Metso process automation know-how means productivity improvement

APC – Advanced Process Control – an autopilotAdvanced control systems based on high level rules aimed at maximizing production performance.

Services – Metso’s life cycle commitmentProduction support, to empower your staff to develop and maintain the system.

The most effi cient processing equipment for all steps in the mineral processMetso is a global leader in the industry - in terms of both knowledge and equipment; we know how to operate mineral processing equipment.

Automation of new and existing plantsWe design automation system for processing plants, and off er the modernisation of process control systems in existing plants, with minimum interruption to your production.

is the diff erence between us and other providers.

Our solutions are always based on your existing equipment and standards.

Reduce costs

Increase production

Automation

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CY-01

1385,5 2112,565,6 727,04,80 1015,7

2,080

Cyclone U/F

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Cyclone O/F

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This print and all the inf ormation hereon is the property ofMetso Minerals and must not be made public, copied or usedin any way detrimental to our intetest. It is loaned subject to

return on demand, unless f urnished under contract prov isions.

Metso Minerals (Sala) ABSweden A1 2-172-000-GO-UH-011

BAttachment 4_Utility Distr

Diagram.igx

LSG 2006-08-17

File Name

Size

Scale Revision

Description Drawn Date

Checked

Approved

Date

Date

Reference Drawing

Sheet

Cont

MITTAL STEEL MEXICO S.A.PROYECTO EL VOLCAN

FLOWSHEET UTILITYGrindingPage 1 of 6

Waterm3/h

FINE ORE BIN

GM-01

WE-01

GMC-01

PX-01

SLP-01A

CY-01

SLP-01B

GM-02

PX-02

SLP-02B

SLP-02A

BF-01

FSP-01A

PROCESS WATERCOOLING SYSTEM

PAGE 6F5

SUPPLY LIMIT

PROCESS WATERGLAND SEAL WATER

HIGH PRESSUREF4PROCESS WATER

LOW PRESSURE SYSTEMPAGE 6

F1

Water0,0

Gland Water1,9

Gland Water2,2

Water166,8

Water65,0

Water65,0

Water501,1

Water263,6

Water1061,5

ATTACHMENT 4 - UTILITY DISTR. DIAGRAM

Design of the control and instrumentation base required for process automationPCD

Automation of crusher plantsMetso is the industry leader for mining crushers, as well as complete crushing plants.

Process control to ensure the choke feeding of crushers, camera and software instruments for particle size measurement of crusher feed and product, power draw measurements, automatic crushing gap monitoring, the detection of screening defi ciencies, all contribute to maximizing the plant performance.

Deliverables PCD - Process Control Diagram

Process Control Diagram

Baseline documentation

Engineering design

Our engineers study the process design and operational data. This may require a process audit to assess key parameters and process dynamics.

Motor control (MCC) facilities need to be audited or designed, to ensure motors for conveyors, pumps etc can be started and stopped and which require variable speed drives.

Based on mass balances and other data, the instrumentation required to eff ectively control your process is chosen. It requires experience to choose the instruments that are fi t for purpose as they vary greatly in price and performance. We recommend advanced instruments only where we know it is required for eff ective process control.

We have supplier agreement with several leading suppliers, allowing us to off er instrumentation at competitive prices.

55

Tail Midds

2005

2003200220012000

2205

2200

2305

23032302230123002500

2105

21002405

2400

SEAL WATER - 7500, PID 1

TO MILL - 5000, PID 4

CYCLONE UF - 1400, PID 1

PROCESS WATER - 7200, PID 1

2455

2450

TO PRIMARY MILL - 1200, PID 12705

2700

Tail Conc Tail ConcTail ConcTail ConcTail ConcConc

2325

2345

2340

2320

2330

2315

2310

2335

2025

2065

Tail Midds Conc

2010

2050

Tail Midds Conc

2015

2055

Tail Midds Conc

2020

2060

2030 2035 2040 2045

2605

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3000

3105

3100

HS3000

LI3105

V23110

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Design of the control and instrumentation base required for process automation

AudioMill

Belt Rips

Density meters

Flow meters

In-line metal assaying

Particle Size Measurement

VisioFroth

VisioRock

Automation of concentrator plantMilling is normally the highest cost of the entire process and grinding effi ciency decides mineral recovery.

Metso has provide some 80% of the bigger mills operating today worldwide. And we know how to best control them, whether they are large Autogenous mills, ball mills or the later generation fi ne grinding equipment, such as Vertimills and SMD’s.

Supplier independentMetso is a supplier of specialized advanced control instruments (Audiomill, VisioFroth, VisioRock ect), control system hardware and software (Metso DNA or any other DCS or PLC based control system) as well as the Metso OCS – advanced process control platform.

We also off er to work with all the main standards used in the mining industry, both for instrumentation and control systems. And we will automate the whole plant, not just limited to Metso process equipment.

New updated documentation

Installation and supervision

Metso also off ers the full range of separation and pumping equipment for concentrators.

Ore and water in mills are controlled for maximum grinding effi ciency, followed by grinding size distribution measurements in the classifi cation system. Control logic for a fl otation process is implemented, using special instruments such as the Metso Visofroth intelligent camera system.

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Process data monitored, analyzed and presented where it is needed,for stable operations and improved productionDCS

Control strategy and system layout

Delivery of instruments and PLC´s

Deliverables DCS - Distributed Control system

Distributed Control System

With the sensors and motor controls implemented the process can be continuously controlled based on readings from the process instruments.

The process operates stably giving better productivity, less maintenance, and more efficient use of operational staff.

With the automation system controlling every step in the process, the operator is free to look for improvements in operational parameters.

Control based on your standardsMain Metso process equipment comeswith a control system, that controls that production system e.g. a crusher or a mill.All such localized control systems must be integrated to an overall control hierarchy, with control rooms that combine the requirements of centralised control for an overview of process performance, to the need to have some control closer to the

equipment. We provide recommendations on control strategy, layouts, redundancy, security levels etc.

You decide on user requirement and hardware and software standards, we do the rest.

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CONTROL ROOM

AUTOMATION ROOM

FIELDFIELD

FIELD FIELD

Operation, Maintenance, Reporting

Star or ring topology redundant Ethernet network

Reporting, Enterprise Integration

Engineering and Maintenace, Asset Management, DNA Historian

Controls, Optimization, Connectivity

Safety instrumented system

Centralized

Distributed

Firewall

Remote Connections

• Updating layered security with hardening, anti-virus and DMZ solutions

• Information through Web Service interfaces • Concurrent solutions for operations and

maintenance

One platform for all control applications

• Integrates major field buses and field asset management

F D TF D T

Wireless solutions for operation and maintenance

Process data monitored, analyzed and presented where it is needed,for stable operations and improved production

Control narratives and programming

Metso DNA process control system. The best possible payback from automationMetso DNA is a single automation system for all functions – process, machine, drive and quality controls. It also covers information management and mechanical and fi eld device condition monitoring. The single system architecture saves on both costs and eff ort, at the same time ensuring open growth for your future challenges.

The intuitive and straightforward Metso DNA user interface enables quick problem solving and effi cient decision-making.

Finding the cause of process disturbances at plants is often challenging. Often information is scattered when you need to be able to compare it on the same screen. By bringing diff erent data into one interface we can create tools that provide a comprehensive overview at a glance, making problem solving and decision making easier.

Final integration, commissioning and training

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An autopilot with a clear mission: maximize production and product qualityAPC

Production analysis, design of operations philosophy and assess process constraints.

Programming high level operations rules, commissioning and evaluation.

Deliverables APC - Advanced Process Control

Advanced Process Control

Advanced Process Control is essentially a mature technology and is installed in many plants around the world. Metso’s Optimizing Control System (OCS©) software is a leader in the field.

OCS© is built around a core of artificial intelligence. The rule set is specific to each application and it effectively takes over most of the set point decision making from the operator, freeing him or her up to focus on higher level tasks – the system

runs the plant and normally these systems have an availability of 99%.

Metso APC differs in our extensive use of model-based control, which has historically meant using population balance models that are automatically calibrated to the plant using advanced statistical methods. In this way a virtual model is available which can be used with optimization algorithms to compute the best operating point for the plant.

Of course, these targets are filtered by the expert system prior to implementation in the plant control system. It is this powerful combination of Artificial Intelligence and deep process expertise in the form of mathematical models that makes Metso the leader in Model-Based Expert Control.

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An autopilot with a clear mission: maximize production and product quality

Training of staff on how to use the system for continued learning and process optimization.

Small investment with immediate paybackThe OCS© will typically result in several percentage points of improvement in productivity. The system comprises a computer into which the operational strategy is programmed.

The OCS© is a relatively small additional investment when compared to the development of a modern DCS.

Using the DCS infrastructure the OCS maximizes the use of the asset, resulting in an immediate payback.

Installed on top of DCS andPLC-based controlsThe OCS© is installed on top of the DCS. Basic logic for control fl ows, densities, motor speed, tank and bin levels etc. are maintained by the rules programmed into the PLC’s that makes up the DCS.

However, more advanced control strategies that well trained operators with good process knowledge implement, are too complex to be programmed in the software used in PLC’s.

The OCS© software system was designed to allow for such complex analysis, e.g. using process data on-line with statistical models, linear programming with constraints, neural networks, fuzzy logic, soft sensor algorithms.

1010

Service commitment secures your automation investmentServices

Our experienced field service team provides on-site support for your operation. As a global service provider, we understand how to provide you with better process performance, improved productivity, maximum plant availability, reliable equipment performance, effective preventive maintenance and improved safety.

Our competence and expertise are at your service full time. Count on Metso’s

Deliverables – Services

Training servicesMetso’s professional training program is based on training modules but always tailored to the needs of your personnel. It involves skills development planning and can be on-site, in a classroom environment or off-site, using e-learning techniques.

Maintenance servicesBased on measured and analyzed information, Metso takes responsibility in prohibiting production breaks and disturbances caused by plant assets’ malfunctions or deteriorated performance.

certified customer service team to assist you in getting the best from your operation.

Control from a distance…Metso can monitor your process from a distance. With this service we can detect potential problems early as well as recommend service and maintenance.

…and local presenceOur local presence is important for our customers. Not just because we can quickly be in place, but also because we know the local conditions, regulations and other requirements.

Continuous improvementAn automation system, especially an optimizing control system, can always be refined and used better. For Metso, it is

Automation Services

Health, safety and environmental servicesWith automation and information management solutions as well as optimization controls, we offer a full scope of customized environmental services.

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Service commitment secures your automation investment

Upgrade servicesWe offer upgrade services, which considerably lengthen the life-time of assets. The condition of the installed base is checked and analyzed, and recommendations for needed upgrades are made.

Spare part servicesSpare part services ranging from on-demand spares to a full scale inventory management solution. Guaranteed availability of the spare parts needed over the whole life cycle.

Performance optimization and monitoring servicesWe can be an integral part of constant performance optimization. Metso offers modern tools for improving performance and availability, as well as for maximizing revenues and minimizing production costs.

important that we are always available as a resource, for continuous improvement and continued economic viability.

Plant diagnostics and upgradesMetso conducts tests and simulations on plant and materials, thus providing the most efficient and economical method of processing a specific material. Testing allows us to match equipment precisely to

the material being processed for new or existing installations.

Operation and maintenance contractsMetso Life Cycle Services are far more than a simple service offering. They incorporate our global knowledge in products and processes to provide solutions that best fit your needs.

Metso services can help you inimplementing the industry best practiceat each step of your operation and achieving the optimum performance from your assets on a sustainable basis throughout the whole lifecycle.

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METSO_MINERALS_CMYK_pc

.pdf 21.5.2008 10:

20:57

Comment:

BHP Billiton is a global leader in the resources industry. Located in Chile’s

Atacama Desert 170 kilometres southeast of Antofagasta, Escondida is

the world’s largest copper producer, producing copper from open pit

mining. Escondida is also one of the lowest cost copper producers.

System continuously maintained in operation.

Retro� t of VisioFrothTM technology for 80 cameras at Los Colorados

concentrator in 2006.

On going contract for designing the VisioFrothTM installation at the

columns circuit at Los Colorados.

BHP Billiton, Chile

Customer: BHP Billiton

Plant: BHP Billiton Escondida in Chile

Ore: Copper

Project

description: Process optimization and automation

Technology/

products: 102 VisioFrothTM cameras and

� otation control at Laguna Seca

concentrator in 2003

Bene� ts: Formal evaluation in 2004:

1.5% increase in Cu recovery

Total bene� ts above 100 Million US$

Year: 2003

Metso Process Solutions

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METSO_MINE

RALS_CMYK_

pc.pdf 2

1.5.2008

10:20:57

Vale, Brazil

Comment:

VALE is the No 1 producer of iron ore and pellets in the world.

In 2006, the quantity of these products shipped was 272.682 million tons.

Customer: Vale, Brazil

Plant: 7 plants in Brazil

Ore: Iron

Project


Technology/

products: Design and implementation

of process automation for

7 pellet plants

Bene� ts: 2-5% capacity increase

1.5-3.5% energy savings

20-40% stabilization of quality

Total bene� ts 200 Million US$

Year: 1999-2005


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METSO_MINERALS_CMYK_pc.pdf 21.5.2008 10:20:57

Iron Ore

Process Optimization and Automation projects

References, Iron Ore

Optimizing Control System (OCS©)Labrador City (Iron Ore Company of Canada/Rio Tinto)Malmberget (LKAB, Sweden)Kiruna column apatite � otation circuit (LKAB, Sweden)Kiruna AG and pebble mills (LKAB, Sweden)Kiruna KA1 concentrator and � otation plant (LKAB)Kiruna KA2 apatite � otation plant (LKAB)Timbopeba (Vale, Brazil)Itabira (Vale, Brazil)Paraburdoo (Hamersley Rio Tinto, Australia)Tom Price (Hamersley Rio Tinto, Australia)Carajas (Vale, Brazil)Germano (Samarco, Brazil)CSN (Brazil)Caue (Vale, Brazil)


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Comment: Codelco is the main copper producer in the world. The Corporation also

controls around 20% of the world reserves of this metal.

Andina produces around 236,356 metric tons a year of � ne copper, it also

delivers 3,308 metric tons of Molybdenum per year.

Bene� ts after � rst tests 2004.

Codelco, Chile

Customer: Codelco

Plant: Codelco, Andina, Chile

Ore: Copper

Project description: Process optimization and automation

Technology/ products: Split cameras, discharge in

pre-crushing, software etc

Bene� ts: 8.9% increase in SAG Mill´s actial

treatment capacity

0.6 kWh/ton in speci� c power

consumption

Additional economic bene� t of

7.8 Million US$, due to 1.6%

improvement in copper purity

Year: 2004-2007


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METSO_MINERALS_CMY

K_pc.pdf 21.5.20

08 10:20:57

Comment:

LKAB is an international high-tech minerals group, one of the world’s

leading producers of upgraded iron ore products for the steel industry

and a growing supplier of industrial minerals products to other sectors.

LKAB supplies customized iron ore products for blast furnaces and

direct reduction.

Pellets are sintered, centimeter-sized spheres of ore with a high iron

content and uniform quality.

Design and implementation of a model-based expert control system,

integrated with the site-level Management Information System

Metso Process Solutions LKAB, Sweden

Customer: LKAB Kiruna

Plant: KA2 Concentrator

Ore: Magnetite (iron)

Project


Bene� ts: 6% increased production reported

by the customer

Year: 1996-2000

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Gold Ore

Process Optimization and Automation projectsReferences, Gold OreOptimizing Control System (OCS©)Troilus Gold (Inmet, Québec, Canada)Lone Tree (Newmont, Nevada, USA)Sadiola (Anglogold, Mali)

Mponeng (Anglogold, South Africa)Geita (Anglogolds, Tanzania)Kloof (Gold� elds, South Africa)Rio Paracatu (Rio Tinto, Brazil)Maricunga (Chile)Telfer (Australia)Pierina (Barrick, Peru)Kopanang (Anglogold, South Africa)Noligwa (Anglogold, South Africa)St. Ives (Gold� elds, Australia)Tarkwa (Gold� elds, Ghana)Iduapriem (Anglogold Ashanti, Ghana)


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Copper and Base Metals Process Optimization and Automation projectsReferences, Copper and Base MetalsOptimizing Control System (OCS©)Escondida (BHP Billiton and Rio Tinto, Chile)

Los Pelambres (Chile)Copperton (Kennecott, Utah)Garpenberg (Boliden, Sweden)Freeport (Indonesia)Greenscreek (Kennecott, Alaska)Toquepala (Peru)Red Dog (Alaska)Brunswick (Noranda, Canada)Andina (Codelco, Chile)Northparkes (Rio Tinto, Australia)CMM Vazante (Brazil)CMM Morro Agudo (Brazil)Antamina (Peru)


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METSO_MINERALS_CMYK_pc.p

df 21.5.2008 10:20:5

7

Pyrometallurgy

Process Optimization

and Automation projects

References, Pyrometallurgy

Optimizing Control System (OCS©)

Iron Ore Pellet Plants

Vitoria, Brazil

Seven straight grate pelletizing plants (Vale)

Ubu, Brazil

Two straight grate pelletizing plants (Samarco)

Hoogovens, The Netherlands

One straight grate pelletizing plant (Corus)

Virginia, Minnesota

One grate kiln pelletizing plant (US Steel)

Lime Calcination

OCS© for standard plants (Svedala, USA)

Greer Lime (USA)

Carmeuse (USA)

Lhoist (USA)

Dryers Control

Kennecott Utah smelter (USA)

Mineraçao Rio do Norte (Brazil)


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Comment: Kennecott Utah Copper Corporation (KUCC), a division of Rio Tinto Group, is a mining, smelting, and re� ning company. Its corporate headquarters are located in Magna, Utah, USA. Kennecott operates one of the largest open-pit copper mines in the world in Bingham Canyon, Salt Lake County, Utah.

Subsequent extensions with• VisioFrothTM (43 cameras)• VisioBallTM, (2 cameras)• Software for KOIS project• New fl otation columns (4), and retrofi ts (20)• VisioRockTM and AudioMillTM experiments, etc

Kennecott, USA

Customer: Kennecott Utah Copper Corporation

Plant: Kennecott, Utah USA

Ore: Copper


Technology/products: Optimizing Control System (OCS©) retro� t on the 4 SAG mills and 8 ball mills

Bene� ts: 5% increase in tonnage attributed to MMPT process automation system

Year: 2002


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METSO_

MINERA

LS_CMY

K_pc.p

df 2

1.5.20

08 1

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Comment:

Freeport-McMoRan Copper & Gold Inc. (FCX) is a leading international

mining company with headquarters in Phoenix, Arizona. Freeport

Indonesia mines, processes and explores for ore containing copper, gold

and silver.

In 2001, Freeport Indonesia decided to migrate the expert system

interface from another platform to Optimizing Control System (OCS©).

In 2002, Rio Tinto and Metso Minerals Cisa jointly re-implemented the

grinding control system in OCS© with DPO logic in OCS©. Several times

faster and much easier to maintain.

SAG mill control with OCS© still almost entirely model-based and well

maintained.

Freeport, Indonesia

Customer: PT Freeport

Plant: Indonesia

Ore: Copper

Project


Technology/

products: Flotation control

172 VisioFrothTM cameras

Bene� ts: Pay back time

estimated by PTFI = 51 days

Recovery increases: 2.6 to 3.9%

for copper

25% frother dosage reduction

Year: 2001-2002


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Comment: AngloGold Ashanti Limited is a global gold producer with 21 operations

on four continents. In South Africa, AngloGold Ashanti operates seven

wholly owned underground mines.

Optimizing Control System (OCS©) for grinding control at Sadiola, Mali,

in 1999. OCS© for grinding control at Mponeng, end of 2001.

OCS© for grinding control at Kopanang in 2004.

OCS© for grinding control at Noligwa in 2005.

Supplemented with VisioRockTM in 2006 at Noligwa.

OCS© also at Iduaipriem, Ghana and Geita, Tanzania.

AngloGold Ashanti, Ghana

Customer: AngloGold AshantiPlant: AngloGold Ashanti Iduapriem, Ghana

Ore: Gold


Technology/products: Blast fragmentation modelling was

undertaken to determine new blast

designs that would decrease the ROM

particle size and rehandle costs.

These blast designs were adopted by

site and represented a 3.5% increase

in total blasting costs. Bene� ts: The results of the � ner fragmentation

were dramatic with an increase in

crushing plant productivity of 21

to 32%.

Year: 1999-2006


Metso Minerals, P.O. Box 74, Terminalsgatan 2, S-231 21 Trelleborg, Sweden, www.metso.com/miningsystems 2844-03-13-ESBL/Trelleborg

Automation project tothe world’s leading mining companies

Metso delivers success. We have more than 100 reference cases around the world. Cases, based on both innovative as well as proven solutions. A proof of this success is that we constantly get new assignments from our customers. Assignments, giving our partners strong competitive advantages and an optimized production.

1 Northgate Exploration - Gold, Copper

2 Cleveland Cliffs - Iron

3 Falconbridge - Copper, Nickel

4 Kennecott - Copper

5 Phelps Dodge - Copper

6 Seminole Electric Cooperative - Limestone

7 Agnico-Eagle - Gold

8 Agrium - Phosphate rock

9 Albian Sands - Oil

10 Mexicana de Cobre - Copper

11 Suncor Energy - Oilsand

12 Minera Escondita - Copper

13 Boliden Westmin - Zinc

14 Huckleberry Mines - Copper

15 Minera Alumbrera - Gold, Copper

16 Tampa Electric - Coal

17 Alumina Partners of Jamacia - Alumina

18 Minera Los Pelambres - Copper

19 Campagnie Minera Inmet - Gold

20 Dragon Products - Limestone

21 Quebec Cartier Mining - Iron

22 Southern Peru Copper - Copper

23 Highland Vallee - Copper

24 IOC - Iron

25 Antamina - Copper

26 Los Pelambres - Copper

27 Los Bronces - Copper

28 BHP - Escondida Copper

1 AngloGold Ashanti - Gold

2 Sar Chesmeh - Copper

3 Akka Gold Mining - Gold

4 Poltava (Svedala) - Iron

5 Cayeli Bakir Isletmeleri - Copper, Zinc

6 Rugby Cement - Limestone, Cement

7 Boliden Atik - Copper

8 Kisladag - Gold

9 Anglo Sadiola - Gold

10 Anglogold Idruapriem - Gold

11 Morila - Gold

12 Kansanshi - Copper

13 Impala Zlmplants - Platinium

14 De Beers - Diamond

15 LKAB - Iron

29 Phelps Dodges Candelaria - Copper

30 Codelco - Copper

31 Codelco Mansa Mina - Copper

32 Vale Sossego - Copper

33 Salobo - Copper

34 RPM - Gold

35 Bunge Cajati - Phosphate

36 Alumbrera - Copper, Gold

37 Vale - Iron

1 Batu Hijau - Copper

2 Porgera - Gold

3 Marandoo - Iron

4 Hamerslee - Iron

5 Bodington - Gold

6 BHP - Iron

7 Fimiston - Gold

8 KWCM - Nickel, Uranium

9 KCGM - Gold

10 St. Ives - Gold

11 Ravenswood - Gold

12 Pasminco - Zinc

13 Cadia - Gold, Copper

14 Ernest Henre - Gold

15 P.T. Freeport - Gold, Copper

16 Kupol - Gold

17 Al Rosa - Diamond

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