BUSINESS •
The first step is to build the mine in a digital world , creating a simulation model or digital shadow . Historically , simulation has been used in feasibility studies for mines to optimise and justify decision making . He notes that simulations are moving in a direction in which they can now be used as a monthly planning tool too to gauge whether targets can be met . Operational changes are evaluated in the simulation model to help reach targets and tested in the digital model before initiating in reality , saving time and money .
4Sight Asset Simulation
“ This is where the process transfers into true digitalisation . To run these models , one requires real-time data from different sources . The greatest challenge lies in gathering the data and having the data on hand in time from the mine . The mine supplies the data , and it is 4Sight ’ s task to build the model and populate it with data .”
He expands on this , noting that the digital twin is handed over to the mine . The mine would then keep data updated and run the monthly reports independently , but sometimes companies such as 4Sight will offer the complete end-to-end service monthly to mines .
The Anglo Platinum feasibility case study In this particular case , Anglo American Platinum had requested a dynamic simulation of the Mogalakwena North Concentrator to review plant design changes required for proposed upgrades . The upgrades under investigation were an Asset Review Improvement Project ( ARIP ), a Low CAPEX and a Debottlenecking Project ( DBP ).
“ The primary objective of the study was to analyse the production capability of the Mogalakwena North Concentrator for each operational scenario by identifying and alleviating bottlenecks ,” says Daling . He notes , “ The lower CAPEX option would produce just 8 % less and cost approximately USD100-million less than the initial design to construct a new comminution circuit in front of the current operation ( Debottlenecking Project ).”
The approach taken was that 4Sight Asset Simulation developed a detailed plant model in the latest Simio™ Software to allow for 3D animation of the processing operations . The 3D dynamic simulation model included conveyors , a grizzly , feeders , screen splits , crushers , a primary mill , bins , silos , and stockpiles .
Illustration of the 3D model
The model tested the following scenarios to establish the best update solution : Current plant operations as the base case ; Asset Review Improvements Project ( ARIP ); Wet Plant Upgrade ; Wet Plant Upgrade with finer blasting ( Low CAPEX Option ) and Debottlenecking Project ( DBP ).
The results of the simulation model aided the customer in making an informed decision on the large capital investment in the South African Mining environment . The study identified key areas of concern , and the simulation model was used as a platform to compare the results of the different upgrade options .
4Sight Asset Simulation 4Sight Asset Simulation 4Sight Asset Simulation
On-site construction
Equipment Utilisation Breakdown
The model also enabled the customer to experiment with multiple improvement options until the key objectives were addressed . The image below displays the throughput comparisons for the different scenarios .
Improvement Option Results .
Critical recommendations were made to assist the customer in their decision-making regarding the upgrade option to implement . The simulation model indicated that the debottlenecking project would deliver the highest throughput , but at the highest capital investment . The most feasible solution in terms of throughput and capital investment was to implement the Low CAPEX option , with just one silo added and a few equipment capacity improvements . This option only sacrificed 8 % on plant throughput and resulted in a multimillion dollar saving . “ The operation is currently still running at rates and achieving the throughput we predicted at the time the study was done . We still run studies for the operation on the simulation to aid in making operational decisions .”
Our typical Return on Investment is tenfold within three months .
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African Mining • July 2022 • 21 |