aggflow sample training agenda
DESCRIPTION
Sample AggFlow training agenda from earlier this year. To attend a training session go to:aggflow.com/trainers.htmlTRANSCRIPT
Maximizing Plant Flow Production
& Profitability
______________________________
AggFlow Training Session
Charlotte, North Carolina
February 18-19, 2009
______________________________
Presented by Bob Bartok
Vice President, Paschal Associates
BS Metallurgical Engineering, Illinois Institute of Technology
MBA, Indiana University
Hosted by Brian Lewis
President & Inventor, BedRock Software
Helping Producers Maximize Profitability
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Day 1 - Agenda
08:15 New User Orientation
AggFlow as a Benchmark
Basic Operations, Selecting Equipment, Connecting Flow Streams, Running the Plant
Sample Problems & Exercises
09:45 Break
10:00 Opening Remarks to Full Training Group
Establishing Goals & Objectives
AggFlow – The Plant Process Benchmark
10:05 Developing a Plant Layout
Getting Started, AggFlow Definitions, Setting User Preferences
Equipment, Flow Streams, Monitors, User Interface; AggFlow Tricks & Tips
Sample Problems & Exercises
12:00 Lunch
13:00 In Depth
Crushers; Database Assumptions; Interpolation of Gradations, Calculation Methods
Screens: Database Assumptions, Calculation Methods, Screen Area Efficiencies
Running The Plant; Red Flags, Maximizing Plant Flows, Applying Specifications
Reports, Graphs, Using Color & Making Notes on Worksheets
Sample Problems & Exercises
14:45 Break
15:00 Advanced Features
Apply specifications, Modes, Blending, Dust Calculations and Conveyors
Creating Multi-page Plants, Importing & Exporting to Excel, Internet Features
Sample Problems & Exercises
16:30 Day 1 Wrap-Up and Q&A
17:30 AggFlow Management Team Reception
Helping Producers Maximize Profitability
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Day 2 - Agenda
08:15 Day 1 Review
Developing a Plant Layout, Crushers, Screens, Reports & Graphs, Advanced Features
08:30 Wash Equipment
Sand Screws, Classifying Tanks, Cyclones & Separators, Black Box
Sample Problems & Exercises
09:30 Water Mass Balance Calculations
Using Water in a Plant, Pumps, Water Pipes, Slurry Pipes, Adding Water Sources,
Spray Bars, Use of Water in Product, Clarifiers & Thickeners, Water Loss
Sample Problems & Exercises
10:45 Break
11:00 Measurements
Sample Buckets, Belt Scales, Measuring Flow Rates & Gradations
Measuring Crushers, Screens, Stock Piles and Validating Calculations in Plant Data
Sample Problems & Exercises
12:30 Lunch
13:30 Fine-Tuning Your Calculations & Plant Designs
Calculation Levels 1, 2 & 3
Bottlenecks AggFlow Cannot Account For
14:30 Final Steps to Improve & Increase Production
Establishing Benchmarks
Comparing Measured Values to Calculated values
Screens, Crushers, HSI’s, Cones
Sample Problems & Exercises
15:30 Day 2 Wrap-Up and Q&A
14:30 Departure
Helping Producers Maximize Profitability
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New User Orientation
AggFlow As A Benchmark
Gradation Definition
AggFlow Equipment Categories
Placing Equipment On The Worksheet
Selecting & Adjusting Specific Equipment
Connecting The Equipment With Flow Streams
Apply Monitors To See Results
“Run” The Plant
Your Best Resource: Select Help, then Open Manual
Simple Plant Setup
Example #1: Setup and Experiment a Simple Plant
Users Around the Globe
Employ AggFlow for:
Total Plant Flow
Simulation & Analysis
Aggregate Mass Balance
Calculations
Water Mass Balance
Calculations
Independent Equipment
Selection
Conduct “What-If?”
Scenarios
Experiment with Different
Equipment & Settings
Switch to Different
Operating Modes
Instantly
Justify New Investment
by Comparing Set-ups
Fine-Tune Equipment
Operation
Identify Plant
Inefficiencies &
Bottlenecks
Reduce Calculation Time
Improve Fuel
Consumption &
Emissions
Customize Plant
Calculations and Reports
Helping Producers Maximize Profitability
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Introduction To AggFlow
BedRock Mission: Help Producers Maximize Profitability
Review processes in existing plants; Find plant process & production bottlenecks
More TPH from same equipment
Assist in correct equipment choices
Accurately target plant production and product mix to meet sales forecast
AggFlow History
Story of the thumb that controlled profitability
Continuous development since 1993
Currently employed in 63 countries
Installed on your computer is the latest version of AggFlow (200811)
Includes Water Mass Balance Calculations & French/Spanish Translation
In This Training Class
We encourage interaction and discussion with your neighbor
We welcome feedback, suggestions & observations during the class
Please do each sample as it will be expanded upon throughout the class
Feel free to repeat and experiment with different options in the samples
OUR GOAL: Tomorrow Afternoon You Will Be Highly Proficient Using AggFlow
Make AggFlow your plant process benchmark
Layout any type of plant
Identify and resolve bottlenecks
Make AggFlow accurate for your plant
Know what questions to ask to improve overall efficiency
Produce plant files, equipment and production reports & graphs
Optimize Plant Production and Maximize Profitability
Helping Producers Maximize Profitability
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Developing A Plant Layout
What AggFlow Is & What AggFlow Is Not: How To Use This Tool
Benchmark
Extremely Sophisticated Calculation Tool (Aggregate : Water)
AggFlow is not artificial intelligence – It does not think for itself
What You Need to Start Using AggFlow:
Initial feed gradation
This is hard to measure given the sizes are typically larger than 8 inches. The most important factor
in the feed gradation is the value passing the first screening point. For example, if the feed is going to
a grizzly feeder with a 5 inch bar opening, then you want an accurate value for the 5 inch percent
passing value.
Example #2: See: Feed Source Secondary Surge Pile Gradation.pdf
Major equipment in the plant
Note: AggFlow plant flow calculations can be performed with or without modeling the conveyors.
Crusher makes, models and settings
Screen sizes and mesh openings
Overall flow of material through the equipment in the plant
AggFlow Menu Definitions
File Edit View Run Database Selected Object Summary Modes Windows Help
Setting User Preferences
User Units Washing Screen Area Display Titles Lines-Grid Tolerance
Display Size Ranges Saving The Plant HTTP Setup Update
Create a Plant From The Hand Drawn Flow Sheet
Example #3: See: Rough Sketch.pdf
Helping Producers Maximize Profitability
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Developing A Plant Layout (continued)
Equipment Placement & Layout
Effect of initial feed on plant accuracy
Equipment descriptions - top level
Flow Stream Layouts
Initial connections
Adjusting bend points
Orthogonal lines
Add Monitors To See Results
“Run” The Plant
User Interface
Zoom features
Multiple selections using shift key
Copy/paste blocks
Graphical Undo
Plant Configuration Advisor – How to use it
AggFlow Tricks
Multiple windows can be open at once
Read the bottom panel for information!
Always keep your program updated
Use your best resource – Open the manual!
Helping Producers Maximize Profitability
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Crushers
Crusher Database Assumptions
Model Selection
Manufacturer limits
Book gradations
Interpolation of Gradations
Reduction Ratio Monitoring
Calculation Method
You are in complete control of the output gradations. AggFlow does not calculate automatically.
AggFlow does not calculate an output gradation based on changes to input gradations
You must specify the output gradation by adjusting the equipment set-up in the program
AggFlow actually ignores the input gradation and relies completely on your output specifications
AggFlow does pay attention to the incoming flow rate and ensures mass balance
Some Impact Crushers Track Input Size Range
Sample of Making Larger Rocks Out of Smaller Rocks
Put sand and gravel into a jaw
Example #4: Sand to Jaw
Example #5: Bad HSI
Helping Producers Maximize Profitability
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Crushers (continued)
Common Mistakes
Modeling mistakes
Not sized correctly
Not set correctly
Operational mistakes
Not maintained
Not fed correctly (Crushers & Screens)
Not loaded near capacity
Book crusher data not correct for equipment application
Helping Producers Maximize Profitability
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Screens
Vibrating Screen Database Assumptions
Model Selection
Adjust as needed
Add new size to database
Calculation Methods
VSMA
Open VSMA sheets
Cedarapids
Deister
Scalper calculation
DBD discussion & efficiency
Screen Area Efficiency
Screen carry over
Set specific size
Adjust sizes and screen efficiency
Refer to results to investigate effects of size and efficiency changes
Using Screen Efficiency To Model Different Mesh Openings
Using the screen efficiency override method
Helping Producers Maximize Profitability
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Screens (continued)
Missing from VSMA
Non-wire deck area requirements
Open area adjustment
Varies from one manufacturer to the next
Multi-openings same deck
Non standard screens
Pep screens
Banana screens
Refer final design to manufacturer
Common Mistakes
Modeling mistakes
Not sized correctly
Equipment not set-up correctly
Other constraints; conveyors, chutes and feeders
Misapplication of equipment
Operational Mistakes
Equipment is not maintained
Screen is not fed correctly
Screen operating parameters
Wrong media
Wrong flow direction
Water amounts
No correction for screen operational parameters
Under loaded screens
Example #6: Under Loaded Screen
Helping Producers Maximize Profitability
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Running The Plant
Red Flags
Note: AggFlow highlights problem areas and equipment exceeding warning levels by turning the
equipment in the worksheet red. However, the program will continue to perform calculations as if there
was no problem. Therefore, you can choose to address, or ignore, red flags at anytime.
Warning Levels
Three warning levels:
Alarms; AggFlow alerts you when calculated results may not match field results
Warnings; Items to be aware of, will not likely affect calculations or results
Missing Limits; Manufacturers have not supplied crusher limits and AggFlow has no limits here
Example #7: Warning Levels
Maximize Plant Production Feature
Runs the plant to maximize crusher capacities
Does not take into account screens & conveyors
Apply Specifications
Product Mix
Helping Producers Maximize Profitability
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Reports, Graphs, Using Color & Making Notes on Worksheets
Saving Settings
Save multiple files (unlimited)
AggFlow View Results defaults to last view saved
Automatic Save (set time period in User Preferences)
File Recapture – in a system crash, AggFlow will provide the option to recapture/save unsaved files
AggFlow File Protection
Turns the Specific AggFlow worksheet into read only (find it under FILE, then Protection)
3-Deck Screen Example
View results & reports for a 3-deck screen.
PDF Reports
Worksheet and results
Title Block Info
Company and name stay with sheet
Run version – identifies the last time the plant was run in the printout
Spreadsheet Reports
Provides complete report and equipment list in spreadsheet format
You can select individual or a selection of line items (hold the SHIFT key)
Coloring and Making Notes on the Worksheet
Highlight, color and make notes on the worksheet
Helping Producers Maximize Profitability
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Advanced Features
Apply Specifications
Specification database
Example #8: Goal - Figure out how to get sample to meet spec
Modes
Modes allow unlimited number of plant setups within each plant file
Example #9: Goal 1 – Use Modes to optimize the same plant for two different products
Example #10: Goal 2 – Use Modes to add a splitter and a new crusher to an existing plant
Blending
Simple Blend Demo
Linear programming info
Example #11: Goal – Determine how many products this plant can make
Dust Calculations
Example #12: Simple Dust Example
Conveyors
Calculation methods
Example #13: Simple Conveyor Example
Helping Producers Maximize Profitability
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Advanced Features (continued)
Creating Multi-Page Plants
Linking Pages
Review of Equipment That Can be Linked
Looping Back to First Page
How Big Can Plants Get?
See: bigPlant.pdf
Example #14: Split plant into three pages
Monitor “Layers”
Example #15: Monitors - Create a TPH and a Settings Monitor Layer
Import/Export to Excel
Example #16: Export AggFlow data to Excel, change it, Import the data back to AggFlow
Internet Features
Get Automatic Updates (regularly!)
Send emails & plant files from within program
Automatic error reporting
Send plant files directly to AggFlow Team for review/help
Send support requests and suggestions to AggFlow Team from within program
Create PDF, JPEG and TIFF files
DAY 1 Wrap-Up – Q&A
Helping Producers Maximize Profitability
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Day 1 Review
Developing a Plant Layout
Initial feed gradation; Major equipment in the plant; Crusher makes, models & settings; Overall
flow of material; Equipment & flow stream layouts; Monitors; Running the plant; Customizing
AggFlow with user preferences; Reports & printouts.
Crusher Selection
Database assumptions; Model selection; Reduction ratios; Calculation methods; Common modeling
and operational mistakes.
Screens
Database assumptions; Model Selection; Calculation methods; Screen area calculations &
efficiencies; Calculation methods; Common modeling and operational mistakes.
Running The Plant
Red flags; Warning levels; Running with Screen area adjustments; Product mix.
Reports & Graphs
Saving settings; PDF reports; Titles & printout labels; Spreadsheet Reports.
Advanced Features
Applying specifications; Modes; Blending: Dust calculations; Conveyors; Multi-page Plants; Monitor
Layers; Importing/exporting to Excel; Internet Features.
Helping Producers Maximize Profitability
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Helping Producers Maximize Profitability
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Wash Equipment
Sand Screw
Basic operation and AggFlow simulation
Classifying Tank
Cyclones & Separators
Black Box – Dewatering Screen
Example of Creating a Wash Plant
Example #17: Create a Wash Plant from Sketch
Helping Producers Maximize Profitability
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Water Mass Balance Calculations
Using Water in an Accurate Plant
Input water into feed
Converting flow streams to slurry pipes
Adding Water Sources
Screen spray bars
Use of water in product
Fresh Water Piping
Pumps
Clarifiers & Thickeners
Water Loss in an Accurate Plant
Example of Creating a Plant with Water Mass Balance Calculations
Example #18: Add Water Mass Balance Features to Wash Plant
Helping Producers Maximize Profitability
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Measurements
Sample Buckets
Quality Control Samples plugged in the flow calculations
Example #19: Install Sample Buckets
Example #20: Demo Excel Interface
Belt Scales
Example #21: Install Belt Scales
Measure Flow Rates and Gradations
Feed material gradation
Variability in feed gradation and making it accurate
Flow Rate
Typical Flow
Primary in-feed not measured
Optimum Flow
Detailed gradation below 4 to 7 inches
% of oversize material
Crushers
Typical
None
Optimum
Input gradation
Output gradation
Helping Producers Maximize Profitability
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Measurements (continued)
Screens
Typical
None
Optimum
Output gradations
Stock Piles
Typical
Gradations
Optimum
Gradations and rates
Methods to Validate Calculations with Plant Data
Statistical history
Field measurements
Observations
Example #22: Real Life Examples of Measurements
Helping Producers Maximize Profitability
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Fine-Tuning Your Calculations & Plant Designs
Why Do So Many Operations Continue Along With Known Bottlenecks?
Calculation Levels
Level 1
Setup with generic data
If you have average material with standard compression crushers this gets you to level 2
If you have impact crushers you may or may not get to level 2
Data varies greatly from one manufacturer to the next
You may need crusher samples to get past this point
Results may be off - but experts report that incremental change is usually very good
Level 2
Take plant measurements to verify results
May identify problems
Experienced aggregate manager uses this model to identify improvements and problems
Level 3
You have enough data to totally optimize production with accurate results
You reach a point where "what if" calculations are consistently accurate and reliable. Use your
experience to estimate where that point is.
Helping Producers Maximize Profitability
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Fine-Tuning Your Calculations & Plant Designs (Continued)
Bottlenecks AggFlow Cannot Account For Or Calculate
Material From the Pit
Transport Equipment
Feeders
Stock Pile Capacity
Surge Pile Capacity
Segregated Material Flow
Transfer Chutes
Helping Producers Maximize Profitability
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Final Steps To Improve & Increase Production
Establish Benchmark
Example #23: Sample Plant File
Example #24: Determine Bottlenecks
Compare Measured Values to Calculated Values
Actual settings do not match current design
Make sure crushers as doing as expected
Screens
Monitor efficiency
Size adequate?
Change mesh openings
Lower rate
Crushers
Try to maintain design capacity
Example #25: Sample File Reviews
Example #26: Evaluate Sample for Accuracy
HSI With Standard Data
Cone With Standard Data
DAY 2 Wrap-Up – Q&A
Helping Producers Maximize Profitability
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Helping Producers Maximize Profitability
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