Frac Sand Plant Optimization Bob Carter, President

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Presentation transcript:

Frac Sand Plant Optimization Bob Carter, President 1-800-334-7431

Characterizing Optimization Operational Performance (Short Term – vs – Sustained) Mining Wet plant Dry plant Load out Fiscal Optimization Personnel – Hiring and Retention Utilities – Power and Water Capital Cost – Growth and Annual Operational Cost Per Ton Maintenance Cost Per Ton Fiscal Projections and Street Expectations Understanding Impact Metrics Mine Feed Gradation Weather and Moisture Change in Product Demand Developing Tools That Drive Optimization In Each Category www.iac-intl.com

Steps To Optimization – Operate System Under Varying Conditions Understanding and Validation of Operating System Dry Plant - Example Understand Current Design and Key “Control Points” in the system Dryer Capability – Actual Operation to Validate Capability Profile WIP Piles on Moisture and gradation Prove out Maximum Capacity with Varying Moisture Log Data on Pressure Drops, Temperature Profiles, etc., Screener Capability Develop Data Metric Across Screeners Quality Impact fn (feedrate, gradation) Screen Configuration fn (gradation) Conveyor and Bucket Elevator Capacity Ensure capacities fn (feedrate, gradation) Dust Collection Waste Handling Capacity f(feedrate, gradation) Pressure Drop, Dryer negative pressure fn (feedrate, gradation) ID fan performance curve fn (feedrate, gradation) www.iac-intl.com

Steps To Optimization – Characterization of Input Wet Plant fn(mine feed) - Example Understand Current Design and Key “Control Points” in the system Mine Feed Variations Changes Maximum Throughput High Waste Material Impacts Hydrosizer and Clarifier Heavy 100 mesh or 4070 Can overload Cyclones Heavy Fines Percentage can impact UFR or Clarifier www.iac-intl.com

Improved “Control Point” Performance Process & Procedural Changes Steps To Optimization – Implement Operational, Control, Data Analytics and Reporting Metric Improved “Control Point” Performance Process & Procedural Changes Develop Analytical Tools Which Optimize Production at Varying Process Conditions Develop Advanced Controls Package To Manage Change in Process Conditions Advanced Trend and Control Charts to Characterize Performance Increased instrumentation and lab data. Lag time reports to evaluate cause/effect timelines for change. Re-design and Retrofit Minimize Pinch Points with Re-design and Retrofit Develop Capital Strategy for Optimization Implement Change and Measure Progress Measure and Report Progress at the Front Line To Drive Ownership Measure and Report Performance by Individual, Crew and Business Unit Develop Evaluation Teams around Continuous Improvement Involve the Front Line on Growth Intiatives www.iac-intl.com

Implement Change In Focus and Operational Methodology Steps To Optimization – Update Financial Models and Capital Improvement Plans Implement Change In Focus and Operational Methodology Target Production Levels Need to Be Achievable and Sustainable Identify Mine Plan and Validate Actual Feed To Adjust Operating Parameters Issue Production Plan Around Sustained Operation at Target Production Levels Factor in Weather or Other Known Pinch Points Outside of Direct Control Modify Predictive Models Factor Improvement in Current Control Points over Time Reduce Costs of Utilities and Unplanned Failure Factor in Improvement From Retrofit and Capital Improvement Processes Share Results At All Levels Recognize Improvement Through Sustainable Objectives Retain, Train and Motivate Workforce Through Success Post Performance Against Goal in the Workplace Develop Plan to Drive to The Next Sustainable Level Success Comes Through Steps, Focus and Commitment. IAC is Committed To Changing the Future Through The Whole Process From Design, Construction, Startup, Data Analytics, Process Optimization and Long Term Operational Support. We win Together! www.iac-intl.com

IAC can Optimize or Design Build Any of These Facilities IAC – EPC, Support Services, Advanced Control, Data Analytics and Optimization Capabilities Patented Dryer/Cooler Rail Loadout Dust Collector OEM IAC can Optimize or Design Build Any of These Facilities Transload Facility Frac Sand Plant – Design & Install www.iac-intl.com

THANK YOU INDUSTRIAL ACCESSORIES COMPANY 4800 Lamar Avenue Mission, KS 66202 800.334.7431 www.iac-intl.com