dynamic modelling and simulation from...
TRANSCRIPT
![Page 1: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/1.jpg)
1
DYNAMIC MODELLING AND SIMULATION FROM FIRST PRINCIPLES FOR COAL PROCESSINGJONATHAN MEYER
![Page 2: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/2.jpg)
AGENDA
• INTRODUCTION
• COAL PROCESSING
• DYNAMIC MODELS
• SYSTEM IDENTIFICATION PROCESS
• SIMULATION RESULTS
• SUMMARY
![Page 3: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/3.jpg)
INTRODUCTION3
![Page 4: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/4.jpg)
COAL BENEFICIATION
INTRODUCTION
COAL VALUE CHAIN:
• Selectively upgrade run-of-mine (ROM) coal to
produce:
• Power station coal
• Metallurgical coal
• Coking coal
4
Mining Beneficiation
Coal product stockpile
Discard
![Page 5: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/5.jpg)
COAL BENEFICIATION
INTRODUCTION
COAL ORE:
• Formation from plants that grew in marshes and swamps some 200 million years ago in South Africa.
Different materials form coal, shale and sand stone.
• Mixing of clay causes ash impurities in the coal.
5
![Page 6: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/6.jpg)
COAL BENEFICIATION
INTRODUCTION
TYPICAL COAL UNIT PROCESSES:
• Primary and secondary crushing and screening:
• Liberation:
6
• Screening:
![Page 7: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/7.jpg)
COAL BENEFICIATION
INTRODUCTION
TYPICAL COAL UNIT PROCESSES:
• Dense medium separation
• Dense medium drums (+50mm)
• Dense medium cyclones (-50mm)
7
“98% of the 53 coal‐preparation plants in South Africa are making use of the DMC”
![Page 8: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/8.jpg)
COAL BENEFICIATION
INTRODUCTION
TYPICAL COAL UNIT PROCESSES:
• Jigging
8
![Page 9: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/9.jpg)
GENERAL CONTROL PROBLEM
INTRODUCTION9
![Page 10: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/10.jpg)
DYNAMIC MODELS10
![Page 11: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/11.jpg)
DYNAMIC MODELS
STEADY-STATE VS DYNAMIC MODELS:
• Steady-state models typically have no time evolution of variables
• Example of steady-state models are metallurgical mathematical models
• Partition curves
• Each relative density (RD) fraction must settle (i.e. reach steady state)
• Sinks are dried and weighed
11
Separation Cutpoint (
Écart Probable Moyen (EPM)
![Page 12: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/12.jpg)
DYNAMIC MODELS
STEADY-STATE VS DYNAMIC MODELS:
• Steady-state models typically have no time evolution of variables
• Example of steady-state models are metallurgical mathematical models
• Coal washability curves
12
![Page 13: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/13.jpg)
DYNAMIC MODELS
STEADY-STATE VS DYNAMIC MODELS:
• Dynamic models incorporate the time evolution of variables
• Typically represented as state-space models
• First principles makes use of conservation of mass and mass of components
13
, ,
, ,
![Page 14: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/14.jpg)
DYNAMIC MODELS
STEADY-STATE VS DYNAMIC MODELS:
• Motivation for dynamic models
14
0%
5%
10%
15%
20%
25%
30%
35%
10%
11%
12%
13%
14%
15%
16%
17%
18%
19%
20%
21%
22%
23%
24%
25%
Freq
uency
% Ash
Peas Ash Results Distribution
May June July Fitted Normal Target Ash Current Mean
![Page 15: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/15.jpg)
DYNAMIC MODELS
COAL UNIT PROCESS MODELS DEVELOPED:
• Primary and secondary crushing and screening:
• Liberation:
15
, , ,
ρ , , , ,
cr
cricr
cr mWdt
dm
,
cr
crocr
mW
,
,
,Inputs:
, = Feed mass flow rate
Outputs:, = Product mass flow rate
= Crusher time constantParameters:
Inputs:
, = Feed mass flow rate
Outputs:, = Oversize mass flow rate, = Undersize mass flow rate
= Material velocity
, , = Screen dimensions
, = Material density
Parameters:
,
,
,
,
,
States:
= Crusher massStates:
= Screen mass
• Screening:
![Page 16: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/16.jpg)
DYNAMIC MODELS
COAL UNIT PROCESS MODELS DEVELOPED:
• Dense medium drum
16
,
,
, , , , ,
, ,
, ,
, ,
, ,
, , ,
,
, ,
, ,
, ,
, ,
, , ,
,
, ,
, ,
, ,
, ,
,,
, = Product mass flow rate, , = Product medium density, , = Product ash percentage, = Discard mass flow rate, , = Discard ash content, , = Discard medium density
, = Feed mass flow rate, , = Feed medium density, , = Feed ash content, , = Feed fixed carbon content
, , = Feed medium content, = Product density, , = Product medium content, = Discard density, , = Discard medium content
, = Feed flow rate, , = Feed ash density, , = Feed medium flow rate, = Product volume, = Product flow rate, , = Product medium flow rate, = Discard volume, = Discard flow rate, , = Discard medium flow rate
Inputs:
Outputs:
Parameters:
States:
![Page 17: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/17.jpg)
DYNAMIC MODELS
COAL UNIT PROCESS MODELS DEVELOPED:
• Dense medium drum
17
![Page 18: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/18.jpg)
DYNAMIC MODELS
COAL UNIT PROCESS MODELS DEVELOPED:
• Dense medium separation
• Dense medium cyclones
18
,
,
, , , , ,
, ,
, ,
, ,
, ,
, , ,
,
, ,
, ,
, ,
, ,,
,
, , ,
,
, ,
, ,
, ,
, ,
, = Overflow mass flow rate, , = Overflow medium
density, , = Overflow ash percentage, = Underflow mass flow rate, , = Underflow ash content, , = Underflow medium
density
, = Feed mass flow rate, , = Feed medium density, , = Feed ash content, , = Feed fixed carbon
content
Inputs:
Outputs:
, = Feed flow rate, , = Feed ash density, , = Feed medium flow
rate, = Overflow volume, = Overflow flow
rate, , = Overflow medium
flow rate, = Underflow volume, = Underflow flow
rate, , = Underflow
medium flow rate
Parameters:
, , = Feed medium content, = Overflow density, , = Overflow medium content, = Underflow density, , = Underflow medium content
States:
![Page 19: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/19.jpg)
DYNAMIC MODELS
COAL UNIT PROCESS MODELS DEVELOPED:
• Dense medium separation
• Dense medium cyclones
19
![Page 20: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/20.jpg)
DYNAMIC MODELS
PUBLISHED LITERATURE FOR FURTHER DETAILS:
• E. J. Meyer and I. K. Craig. The development of dynamic models for a dense medium separation circuit in
coal beneficiation. Minerals Engineering, 23(10):791-805, 2010.
• E. J. Meyer and I. K. Craig. Development of a steady-state partition curve from a dense medium cyclone
dynamic model in coal beneficiation. In Proceedings of the 18th IFAC World Congress, Milano, Italy, volume
18, pages 10523-10528. IFAC, IFAC, 2011. doi: 10.3182/20110828-6-IT-1002.02846.
• E. J. Meyer and I. K. Craig. Coal dense medium separation dynamic and steady-state modelling for process
control. Minerals Engineering, 65:98-108, 2014.
20
![Page 21: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/21.jpg)
SYSTEM IDENTIFICATION PROCESS21
![Page 22: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/22.jpg)
SYSTEM IDENTIFICATION PROCESS
SOLVE PARAMETERS FOR DYNAMIC SYSTEM:
• State-space representation
• Input/output data
• Compute norm
• Minimise norm solving for parameters
22
, ,
, ,
![Page 23: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/23.jpg)
23
SIMULATION RESULTS
![Page 24: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/24.jpg)
BENEFICIATION PROCESS
SIMULATION RESULTS24
Drum screen model
Cyclone screen model
Drum model
Cyclone model
![Page 25: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/25.jpg)
DENSE MEDIUM SEPARATION PLANT MODEL INPUT DATA
SIMULATION RESULTS25
Plant feed mass flow rate
Drum medium density
Cyclone medium density
![Page 26: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/26.jpg)
PLANT MODEL INPUT DATA - ASH
SIMULATION RESULTS26
RECONSTITUTE FEED ASH USING COAL WASHABILITY AND PARTITION CURVE:
• M-Curve fit (product ash vs yield) from coal washability
• Obtain partition curve by reducing dynamic model to steady-state model
• Calculate feed ash
, ,
, ,
![Page 27: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/27.jpg)
DRUM SCREEN MODEL
SIMULATION RESULTS27
Fit (%) 98.9
Corr. 1.00
![Page 28: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/28.jpg)
DRUM MODEL
SIMULATION RESULTS28
Fit product(%)
69.2
Corr. product 0.95
Fit discard(%)
39.3
Corr. discard 0.81
![Page 29: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/29.jpg)
DRUM MODEL ASH
SIMULATION RESULTS29
Fit product ash (%)
41.2
Corr. Product ash
0.87
Fit discard ash (%)
13.3
Corr. Discard ash
0.60
![Page 30: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/30.jpg)
CYCLONE SCREEN MODEL
SIMULATION RESULTS30
Fit (%) 96.2
Corr. 1.00
![Page 31: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/31.jpg)
CYCLONE MODEL
SIMULATION RESULTS31
Fit product(%)
44.8
Corr. product 0.86
Fit discard(%)
25.0
Corr. discard 0.82
![Page 32: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/32.jpg)
CYCLONE MODEL ASH
SIMULATION RESULTS32
Fit product ash (%)
25.0
Corr. Product ash
0.72
Fit discard ash (%)
1.5
Corr. Discard ash
0.46
![Page 33: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/33.jpg)
SUMMARY33
![Page 34: DYNAMIC MODELLING AND SIMULATION FROM …sacac.org.za/wp-content/uploads/2016/04/5_dynamic_modelling_j_meyer...1 dynamic modelling and simulation from first principles for coal processing](https://reader034.vdocuments.net/reader034/viewer/2022051321/5aee2ae67f8b9a903190c087/html5/thumbnails/34.jpg)
SUMMARY34
MODEL FIT RESULTS SUMMARY:
Model measure Fit (%) Correlation
Drum screen 98.9 1.00
Drum product 69.2 0.95
Drum discard 39.3 0.81
Drum product ash 41.2 0.87
Drum discard ash 13.3 0.60
Cyclone screen 96.2 1.00
Cyclone product 44.8 0.86
Cyclone discard 25.0 0.82
Cyclone product ash 25.0 0.72
Cyclone discard ash 1.5 0.46