Kennecott Utah Copper’s Information System A.E. Lamb, D.J. Sonntag, W.P. Wride 2000 OSI Software Users’ Conference April 2 - 5, 2000 San Francisco, California

Kennecott Utah Copper’sInformation System

Kennecott Utah Copper’sInformation System

A.E. Lamb, D.J. Sonntag, W.P. Wride

2000 OSI Software Users’ Conference

April 2 - 5, 2000

San Francisco, California

Kennecott’s Foundation for Excellence

Kennecott’s Foundation for Excellence

HistoricalData

Informationfor

Action

Feedback

KUC Information SystemKUC Information System

General Information

PI System

Uses

General InformationGeneral Information

Historical (The Hill)Current (The Pit)KUC Process

The Hill General InformationThe Hill General Information



The Pit General InformationThe Pit General Information

Kennecott Annual Production Revenue

Copper

Molybdenum Oxide

Gold

Silver




KUC Process KUC ProcessGeneral InformationGeneral Information

The Bingham Canyon MineThe Bingham Canyon Mine

Move 300,000+ tons/day Data collected-

truck movementstons hauled per truckcrusher parameters

KUC ProcessKUC Process

The ConcentratorsThe Concentrators

Copperton and North Concentrators 172,000 tons of ore processed/day Data collected (14,000 points)-

mill speed and powerthroughput and flowratesonline x-ray assays


The SmelterThe Smelter

Flash smelting, flash converting technology 720-lb, 99.5% Cu anodes Data collected (13,000 points)-

furnace temperaturesflowratesassays


The RefineryThe Refinery

Anode Cu —» cathode Cu in 10 days Cathodes are 99.99% Cu Data collected (1700 points)-

electrolytic tank conductivityanodes’ residence timeequipment status



General Information

PI System

Uses

PI SystemPI System

Instrument InterfaceCompression AlgorithmUser InterfacePlants Operating With PI


General Information

PI System

Uses

UsesUses

Operations / Maintenance Troubleshooting

Process OptimizationProcess Online MonitoringCreating Production ReportsMaintenance Scheduling



Unusual Caustic Usage Oxidation-Reduction Potential (ORP)

Control Problem

UsesUses

Caustic Valve OperationCaustic Valve Operation

Anodes' Caustic Usage

AnodeCaustic

OffgasScrbr

ScrbDC245BpH

9/20/99 11:00:00 AM 9/20/99 09:00:00 PM10.00 Hour(s)

LIC 527501.OUT

%

AIC 527508.OUT

%

AIC 527510.OUT

%

-250

-200

-150

-100

-50

0

50

-300

150

0

150

0

1502.2801E-002

0.

0.

LIC 527501.OUT

%

AIC 527508.OUT

%

AIC 527510.OUT

%

UsesUses



Unusual Caustic Usage Oxidation-Reduction Potential (ORP)

Control Problem

UsesUses

Faulty Reagent ValveFaulty Reagent ValveUses

Working Reagent ValveWorking Reagent ValveUsesUses

UsesUses



Process OptimizationProcess Optimization

Monitoring Boiler Pressure Increase Furnace Process Control Issues

UsesUses

Holman Boiler Warm-up CurveHolman Boiler Warm-up CurveUsesUses

Enter Starting Date: 7/6/99 Enter Starting Time: 11:20

Holman Boiler Pressure - Warm Up Curve

0

100

200

300

400

500

600

700

800

900

7/6

/99

11

:02

7/6

/99

11

:16

7/6

/99

11

:31

7/6

/99

11

:45

7/6

/99

12

:00

7/6

/99

12

:14

7/6

/99

12

:28

7/6

/99

12

:43

7/6

/99

12

:57

7/6

/99

13

:12

7/6

/99

13

:26

7/6

/99

13

:40

7/6

/99

13

:55

7/6

/99

14

:09

7/6

/99

14

:24

7/6

/99

14

:38

7/6

/99

14

:52

7/6

/99

15

:07

7/6

/99

15

:21

7/6

/99

15

:36

7/6

/99

15

:50

7/6

/99

16

:04

7/6

/99

16

:19

7/6

/99

16

:33

7/6

/99

16

:48

7/6

/99

17

:02

7/6

/99

17

:16

Time

Pre

ssu

re (

psi

g)

RecommendedPressure (psig)

Actual Pressure(psig)

Update Actual Holman Boiler Pressure Graph

Process OptimizationProcess Optimization

Monitoring Boiler Pressure Increase Furnace Process Control Issues

UsesUses

FSF/FCF Process Control IssuesFSF/FCF Process Control Issues

Sampling and Process Data AvailabilityLack of Feedback Control on both

furnacesConcentrate & Matte Grade Variations

to the FSF/FCF

UsesUses

Furnace Interface LogicFurnace Interface Logic

User Interface(visual basic)

Furnace Model

Access Excel

PI DatabaseLab Database

DDE

Matte, S-slag, C-slag,S-feed,

C-feed, DRCon, 040 bin

Courier Cu, Fe, S, CaO, SiO2

Temperature

Feedback CalculationsData Archiving

CRS

UsesUses

UsesUses



Process Online MonitoringProcess Online Monitoring

Smelter Hot Metals Operation Powerhouse Operating Parameters

UsesUses

Process Online MonitoringProcess Online Monitoring

Smelter Hot Metals Operation Powerhouse Operating Parameters

UsesUses

Powerhouse Operating ParametersPowerhouse Operating Parameters

Factors Affecting STG Steam Temperature

LPStmtoSTGTr SHtrExpStm SH Stm To PH SHtrExitGas Comp#1StmOut HotHexTo1st

3/20/00 09:00:00 AM 3/20/00 11:00:00 AM2.00 Hour(s)

TI 580800

TIC546499B

TI 546458

TIC 546499A.OUT

TI 546438

TIC 546472.OUT450

500

550

600

650

700

400

800

400

800

400

800

0

300

400

800

0

100553.73

664.32

565.34

84.916

456.16

64.631

TI 580800

TIC546499B

TI 546458

TIC 546499A.OUT

TI 546438

TIC 546472.OUT

UsesUses

UsesUses



Creating Production ReportsCreating Production Reports

Efficient Use of Manpower Timely Decision Making

UsesUses

Kennecott Productivity Increase Since 1981 (Tons Copper Produced/Employee)

31

129

1981

Current

UsesUses

Creating Production ReportsCreating Production Reports

Efficient Use of Manpower Timely Decision Making

UsesUses

UsesUses




General Information

PI System

Uses

HistoricalData

Informationfor

Action

Feedback

Kennecott’s Foundation for the FutureKennecott’s Foundation for the Future

Questions?Questions?

Documents

Kennecott Utah Copper’s Information System A.E. Lamb, D.J. Sonntag, W.P. Wride 2000 OSI Software Users’ Conference April 2 - 5, 2000 San Francisco, California