Page 1 Next Generation Software Technologies using 3D Emulation for the Mining Industry Rev. 3.0
Page 2 Who Are We ? Multidiscipline Dynamic Modeling & Simulation Products and turnkey solutions provider for: Naval military sector General industry The products and services cover: Process engineering, Performance Analysis, Real-time Control & Optimization and Training Systems
Page 3 Liquids Liquids Gases Gases Ventilation Ventilation Electrical generation and distribution Electrical generation and distribution Controls Controls Propulsion Propulsion Cause & Effect and decisional logic Cause & Effect and decisional logic Our Products Modeling Capabilities Multidiscipline Dynamic Modeling & Simulation for:
Page 4 Requirements Functional and Detailed Design Conceptual Design Product Definition Design Our Products Application Lifecycle
Page 5 Requirements Functional and Detailed Design Conceptual Design Validated Systems Virtual Testing Product Definition Performance Analysis AnalysisandTesting Our Products Application Lifecycle
Page 6 Requirements Functional and Detailed Design Conceptual Design Operational Systems Training Simulations Validated Systems Virtual Testing Product Definition Performance Analysis Operator Training Our Products Application Lifecycle
Page 7 Real-time Control & Optimization Deployable System Requirements Functional and Detailed Design Re-fit and upgrades Conceptual Design Operational Systems Training Simulations Validated Systems Virtual Testing Product Definition Performance Analysis ControlandOptimization Our Products Application Lifecycle
Page 8 Mine Ventilation Optimization “The Business Case” 35-50% of operating cost 1 – 30 M$ / yearVentilation = 35-50% of operating cost 1 – 30 M$ / year deeper ore bodiesNeed to extract deeper ore bodies Required energy increases exponentially maxed-outOften ventilation equipment is already maxed-out Energy prices increaseEnergy prices continue to increase Carbon emission added to financial statementsCarbon emission costs may be added to financial statements Aggressive energy managementAggressive energy management inevitable to remain competitive yetNo compelling solution was available yet
Page 9 Mine Ventilation Optimization “The Solution” Expected benefits: 30 to 50+ % energy savings 30 to 50+ % energy savings Improved air distribution where needed, when needed Improved air distribution where needed, when needed Enhanced safety Enhanced safety Dynamic trackingDynamic tracking of diesel machinery demandVentilation calculation demand for each of the mine work zones High fidelity modeling and simulation of the ventilation network real time mass balanceCalculation of a real time mass balance for the ventilation network Control and optimizationControl and optimization of air distribution and required electrical energy Setpoint optimizationSetpoint optimization for all fans and airflow regulators OPCSetpoints sent to the physical control devices via OPC
Page 10 1.Engineering Suite 2.OPC Server 1.GENESIS 32 2.DataWorX 3.BridgeWorX Mine Ventilation Optimization “The Iconics Integration” A turnkey solution that integrates complementary products 4.GENESIS 64 5.WebHMI 6.ReportWorX
Page 11 Mine Ventilation Optimization Functional Architecture Server All information interchange
Page 12 Server Battery-powered wireless mesh network Dynamic tracking of machinery location and operating status or Mine Ventilation Optimization Functional Architecture
Page 13 Server Engineering Suite A control system comprising: Dynamic ventilation demand calculation Physics based high fidelity ventilation network model Regulatory analog and logic controls Air flow optimizer Energy optimizer or Mine Ventilation Optimization Functional Architecture
Page 14 or Server Engineering Suite Calculates ventilation demand from tracking information Model performs a real time mass balance Real-time results for flow, pressure, velocity and temperature Mine Ventilation Optimization Functional Architecture Smart P&IDs
Page 15 or Server Engineering Suite Real-time analog and logic control Air flow and energy optimization Fans and air flow setpoints sent to PLCs via OPC Mine Ventilation Optimization Functional Architecture Control Schematics
Page 16 Server Engineering Suite Live MS-Excel link to simulation, controls and optimizer. or Mine Ventilation Optimization Functional Architecture
Page 17 Server Engineering Suite or Dynamic and interactive performance analysis and tuning. Mine Ventilation Optimization Functional Architecture
Page 18 PLCs Bi-directional communication to PLCs and other external systems. Covers communication redundancy. Server Engineering Suite or Mine Ventilation Optimization Functional Architecture
Page 19 Server Engineering Suite or PLCs provides the user interface for surface operators. WebHMI provides user interface to underground miners. RerportWorX also provides system operation, events and alarm reporting. Mine Ventilation Optimization Functional Architecture
Page 20 PLCs Server Engineering Suite Mine Ventilation Optimization “The Next Generation” or
Page 21 Mine Ventilation Optimization “Smart P&IDs”
Page 22 Mine Ventilation Optimization “Controls and Optimizer”
Page 23 Mine Ventilation Optimization “Excel as an Engineering Aid” Microsoft Excel dynamic link to the simulation model
Page 24 Mine Ventilation Optimization “Tracking” Tracking provides machinery location and operating status Ventilation demand calculated from the tracking results
Page 25 Mine Ventilation Optimization “Tracking” Dynamic demand calculation based on tracking
Page 26 Mine Ventilation Optimization “Tracking” Dynamic demand calculation based on tracking
Page 27 Mine Ventilation Optimization “Control modes” Manual; operator sets a fan speed or an air flow regulator opening position,Manual; operator sets a fan speed or an air flow regulator opening position, Auto-CFM; operator sets a desired CFM flow for a fan or air flow regulator,Auto-CFM; operator sets a desired CFM flow for a fan or air flow regulator, Auto-VOD; optimizer calculates optimal required air flow as per results of the dynamic tracking.Auto-VOD; optimizer calculates optimal required air flow as per results of the dynamic tracking.
Page 28 Mine Ventilation Optimization Conclusion This is more than “Control & Optimization” Challenge existing and new design performance through analysis Challenge existing and new design performance through analysis Quickly evaluate alternatives Quickly evaluate alternatives Test drive a design Test drive a design Assist in adequate equipment sizing Assist in adequate equipment sizing Validate mine expansion as planning tool Validate mine expansion as planning tool Enable deeper mining with available ventilation resources Enable deeper mining with available ventilation resources This solution is also applicable to other industries!