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07 SmartMill rev-

The document discusses ABB's advancements in grinding applications, focusing on the benefits of variable speed drive solutions for mill systems. Key advantages include improved process stability, efficiency, and reduced maintenance costs, driven by the ability to optimize operations in response to varying ore grades. The SmartMill™ technology enhances mill performance through predictive control and real-time data, ultimately leading to increased throughput and reduced operational costs.

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roshan tyr
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17 views21 pages

07 SmartMill rev-

The document discusses ABB's advancements in grinding applications, focusing on the benefits of variable speed drive solutions for mill systems. Key advantages include improved process stability, efficiency, and reduced maintenance costs, driven by the ability to optimize operations in response to varying ore grades. The SmartMill™ technology enhances mill performance through predictive control and real-time data, ultimately leading to increased throughput and reduced operational costs.

Uploaded by

roshan tyr
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ABB CUSTOMER DAY, TEHRAN, MAY 22, 2017

ABB in grinding applications


SmartMillTM
Daniel Ryf, Sales Support Manager
Grinding systems
Where does the journey go to?

Trends
– Larger units (Power, Diameter) - Economy of scale
– Elimination of maintenance-intensive mechanical components, subject to wear and limited life
time
– Key drivers: availability, process optimization, production cost and efficiency
These trends are enabled and supported by intelligent variable speed drive solutions, taylored
to the industry and application

May 18, 2017 Slide 2


Upgrade of a mill drive system
Benefits of the latest technology

Customer’s pain Customer’s gain


Drivers for replacement of the existing Solve the issue of the existing system
system: and provided further value as:
– Mill drive system close to end of – Increase process stability
lifetime – Increase grinding efficiency
– Mill drive system with availability issues – Reduce maintenance cost
– Mill drive system limiting throughput – Reduce consumables
– Commodity prices down – Increase drive efficiency
– Low ore grades

The upgrades are mainly driven by availability or throughput.


But today’s technology offers multiple additional benefits in operation, maintenance and
production cost

May 18, 2017 Slide 3


Fixed speed versus variable speed
Why variable speed?

Process optimization
Allows the operators react to the different ore grades and other changes in the process
correspondingly.

Wear reduction
The variable speed offers the ability to minimize the wear of equipment with the constant use.
The impact of the balls in the inner structure of the mill can be avoided by reducing the rotation
speed.

Smooth operation
The start of the mill with variable speed is smooth both for the network and for the mechanical
equipment.

May 18, 2017 Slide 4


Variable speed operation
Process optimization / Wear reduction

SAG mill
Variable speed operation
of SAG mills is state of the
art

May 18, 2017 Slide 5


Variable speed operation
Process optimization / Wear reduction

Ball mill
Sometimes ball mill runs for
short time with low speed,
e.g. when SAG mill is down
– Speed low enough, no
grinding
– Ball mill does not need to
be washed out, isolated
and stopped
– But ball mill stays on line
running and speed is
ramped up again as soon
as feed comes again

May 18, 2017 Slide 6


Variable speed operation
Smooth operation by soft electrical starting

§ No high inrush current


§ Very smooth for the
electrical supply network
§ Not a true constant
torque application =>
speed influences torque
§ Use of variable speed
reduces start torque and
related stresses

MOTOR SPEED MASTER [rpm]


MOTOR SPEED FOLLOWER [rpm]
MOTOR TORQUE MASTER [%]
MOTOR TORQUE FOLLOWER [%]
NETWORK CURRENT [%]

May 18, 2017 Slide 7


Variable speed operation
Smooth operation by soft torque transmission

– Trend: higher power and torque transfer per


pinion
– Pinion & ring gear teeth getting wider. Teeth
width for 2 x 6340 kW:
– SAG mill 1‘016 mm
– Ball mill 1‘050 mm
– More challenging to have a perfect alignment
– If no perfect alignment, torque transfer not
over complete teeth surfaces, but over hot
spots

Beneficial to avoid rough starts and torque


spikes during all operation conditions

May 18, 2017 Slide 8


Variable speed operation
Load sharing on dual pinion drives

Fixed speed drive Variable speed drive


Inaccurate load sharing (up to 10%) Amazing accurate load sharing:
– No active load sharing possible – Torque difference typically below 1%
– Only some inherent load sharing of actual torque
through the steep torque-speed – Torque difference during starting and
characteristic of the two ASM controlled roll back clearly below 3%

May 18, 2017 Slide 9


Ring-geared mill drive (RMD)
Start sequence with VSD

CONFIDENTIAL - We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
© ABB Group forbidden. Copyright © ABB Switzerland Ltd.
Variable speed operation
Mill Application Features

Protection Operation Maintenance Advanced Control


– Frozen charge – Softstarting – Creeping – Predictive control
protection – Frozen charge – Automatic (SmartMillTM)
– Coupling remover positioning
supervision – Mill load sharing
– Standstill – Controlled roll
detection back
– Broken teeth – Mill power ride
detection through
– Over-duty cycle
– Oscillation
damping
– Torque slop
limitation

May 18, 2017 Slide 11


Mill application features
Short video

CONFIDENTIAL - We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
© ABB Group forbidden. Copyright © ABB Switzerland Ltd.
Mill application features
Frozen charge protection

Frozen charge
§ Under normal conditions, the charge in a
mill starts to cascade as soon as a certain
mill angle is reached.

§ In rare cases, for instance after long


suspended mill operation, the charge can
settle in a large lump and sticks to the mill
liners.

§ Frozen charge protection is a system that


prevents that “lump of ore” to be lifted and
then dropped, that could cause damage to
mill liners, bearings and even mill shell.

May 18, 2017 Slide 13


Mill application features
Creeping

Cascading mill charge

Start with 10% rated speed Motor speed 3.3 rpm


(mill speed ~1.0 rpm) (mill speed ~0.2 rpm)

May 18, 2017 Slide 14


SmartMill ™
How to get most out of your mill?

Ore feed
Optimizing mill operation
Ore size
– How does a change of
feed, speed, water, flap
gate (coarse to fine) Returned ore
influence load, power
and torque? Feed water Fill indicator
– Are there any
nonlinearities?
– How does the operator
deal with these Mill speed Torque
variables?
– How good and stable is
your PID?

May 18, 2017 Slide 15


SmartMill ™
Solution approach

Factors influencing mill


efficiency Our approach Benefits
– Material properties – Predicting the behavior – Increased efficiency
– Rotational speed of the in the future based on a – Stabilized mill load
mill mathematical model – Reduced energy
– Mill feed adjusting model consumption
parameters on past
– Internal mill liners behavior – Extended mill lifetime
profile – Improved operator
– Actively use variable
– Ball charge + water + speed on the mill based productivity
ore on real time data from – Helps you achieve
the process. optimum particle size
– Give flexibility to
operators, while
keeping the
constraints.

May 18, 2017 Slide 16


SmartMill ™
Mathematical concepts behind optimization

State-of-the-art control
technology
– Model predictive control Past Future
(MPC)
– Moving-horizon Reference trajectory
estimation (MHE) Predicted output
Measured output
– Advanced parameter
Predicted control input
estimation techniques Past control input

Prediction horizon

Time

May 3-5, 2017 Slide 17 Mining User Conference 2017, Stockholm


Results from APC Grinding in a copper mine
Particle size and mill load controlled

Particle size Mill load

Standard deviation of particle size decreased by 36%


Standard deviation of mill load decreased by 79%
Production increased by 4%

May 3-5, 2017 Slide 18 Mining User Conference 2017, Stockholm


Return of investment analysis
Key elements of a trade-off

Capital costs (CAPEX) Operating costs (OPEX)


– Mechanical – Energy expenses
– Electrical – Cost of loss of production
– Freight related to unavailability
– Foundation – Cost of downtime to implement
– Cabling new solution
– Installation and commissioning – Possible earnings or costs with
– Capital spare parts different control/technologies
– Maintenance costs

Payback time:
(CAPEXnew – CAPEXexisting) / (OPEXexisting – OPEXnew) * 12

May 3-5, 2017 Slide 19 Mining User Conference 2017, Stockholm


SmartMill: intelligent variable speed mill drive solutions
Conclusions

Benefits Opportunities and Financials

Performance benefits Opportunities


– Increased throughput – No constraint violation: less unexpected
– Increased grinding efficiency downtimes
– Extended mill consumables lifetime – More flexibility to react to different ore
Automation benefits grades
– Automatic selection of optimal set Financials
points: improved operator productivity – Fast payback
– Improved control over particle size
Maintenance benefits
– Reduced stresses on mill components:
increased up-time
– More reliable technology: increased
availability

May 3-5, 2017 Slide 20 Mining User Conference 2017, Stockholm

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