From Material Balance to Metallurgical and Operational Accounting. Luis Yacher Sigmafine Users Conference San Francisco, April 23, 2012

Transcription

1 From Material Balance to Metallurgical and Operational Accounting Luis Yacher Sigmafine Users Conference San Francisco, April 23, 2012

2 AGENDA CONTEXT, the Overall Picture The Role of Data Reconciliation and Material Balance Data Reconciliation and Material Balance, AMIRA Reference Model Data Reconciliation and Material Balance, Execution Fast Tour The CORE, the Process Model The CORE, the ENHANCED Process Model The System Architecture Met Accounting Implementation SF in M&M

3 CONTEXT, Met. & Op. Accounting, the Overall Picture Business Systems Total Values Line/Area Values Consumables Production Stats. Avg, Cummulated Process Values Operational KPI Real vs. Program? What is needed in the gap? Inventories Down Times Levels Ore Characteristics Real time Data Lab Data Mine Systems Data Equipment Data Analysis Flows PROCESS

4 CONTEXT, Met. & Op. Accounting, the Overall Picture Business Systems Total Values Line/Area Values Consumables Production Stats. Avg, Cummulated Process Values Operational KPI Real vs. Program Data Validation Aggregation Operational Contexts Adjustments Calculations Functional contexts Reconciliation Inventories Down Times KPI s calcs Levels Info. Workflow Mgmt. Ore Characteristics Real time Data Lab Data Mine Systems Data Equipment Data Analysis Flows PROCESS

5 The Role of Data Reconciliation and Material Balance just in one slide For: Material Flows, Inventories and Analysis Process Water, Water make-up, Inventories and consumptions Effluents From Mine to Port: To get a single, objective and shared version of the truth For every process area and line For every critical process HOW? Starting from: Real time Data Lab Data Mine Systems Data Equipment Data A formal procedure to get a set of data That complies with the following basic principle: - = + Inventory 0 what what goes in goes out variation

6 Data Reconciliation and Material Balance, AMIRA Reference Model DATA IS AN ASSET DATA IS SHARED AND ACCESIBLE DATA QUALITY IS FIT FOR PURPOSE DATA IS SECURE DATA IS NOT DUPLICATED (AMIRA P754)

7 Data Reconciliation and Material Balance, AMIRA Reference Model DATA MANAGEMENT MET ACCOUNTING MODEL BALANCE REPORTING TRACEABILITY Data Results Meta Data

8 Data Reconciliation and Material Balance, AMIRA Reference Model Data Collection Data PreFiltering Data Processing Data Validation MET ACCOUNTING MODEL DATA MANAGEMENT Error Identification Errors Calculation BALANCE MET ACCOUNTING MODEL Reconcilation Results Analysis Close and Publish

9 Data Reconciliation and Material Balance, AMIRA Reference Model Data Management DATA COLLECTION (ENTRY) DATA COLLECTION FROM VARIOUS SOURCES (SCADA, Plant Historian, LIMS) PIAF Data References (PI, SQL Queries, Ad Hoc queries) AUDITABLE DATA ENTRY Manual Checks Range Checking Double entry and validation

10 Data Reconciliation and Material Balance, AMIRA Reference Model Data Management DATA PREFILTERING NO DATA AVAILABLE (Instrument maintenance, Interface Error, DCS Error, etc.) Use the last value Use the average for the last x values Use signal from close meter PIAF Analysis Rules PIAF Formulas PI ACE

11 Data Reconciliation and Material Balance, AMIRA Reference Model Data Management DATA PROCESSING AGGREGATE DATA CALCULATE ESTIMATORS (VIRTUAL SENSORS) PIAF Analysis Rules PIAF Formulas PI ACE

12 Data Reconciliation and Material Balance, AMIRA Reference Model Data Management DATA VALIDATION CHECK DATA BEFORE RECONCILIATION AUTHORIZED CHANGES PIAF Tools Excel Add Inn Ad Hoc functions

13 Data Reconciliation and Material Balance, AMIRA Reference Model Data Management ERRORS ID AND CALCULATIONS DEFINE TOLERANCES BASED ON STATISTICAL ANALYSIS Variogram Application

14 Data Reconciliation and Material Balance, AMIRA Reference Model Metal Balance MET ACCOUNTING MODEL PRIMARY SECONDARY ACCOUNTING MODELS MODELING DIFFERENT PROCESS (Concentrators, Smelters, Refineries, Leaching, SX EW, etc.) HANDLE MODEL CHANGES (Model Versioning) SIGMAFINE Templates and Elements PROCESS BOOK Representation

15 Data Reconciliation and Material Balance, AMIRA Reference Model Metal Balance RECONCILIATION SOLVER FOR MASS AND ASSAYS ADJUSTMENTS SOLUTION SIGMAFINE ALGORITHM Ν 2 Raw i - Reconciled i ) Minimize Σ ( Absolute Tolerancei i = 1

16 Data Reconciliation and Material Balance, AMIRA Reference Model Metal Balance RESULTS ANALYSIS ADJUSTMENTS REVIEW GROSS ERROR DETECTION BIAS DETECTION IMBALANCE ANALYSIS Meter 18 SIGMAFINE TOOLS Test1, Test2 statistical parameters for variable ibl deviation evaluation Test3, Test4 statistical parameters for imbalance evaluation Influence determination Meter y = x meter18 Linear (meter18) Meter y = x y = x y = x meter8 Linear (meter8) meter11 Linear (meter11) Linear (meter11)

17 Data Reconciliation and Material Balance, SCM SF Execution Fast Tour Shall be a MET user experience EXECUTE REVIEW (Audit) CONFIGURE 17

18 Data Reconciliation and Material Balance, Execution Fast Tour SELECT (CREATE) A BALANCE CASE 18

19 Data Reconciliation and Material Balance, Execution Fast Tour Analysis Functions Balance Functions Run and Publish Functions 19

20 Data Reconciliation and Material Balance, Execution Fast Tour DATA Check and Validation 20

21 Data Reconciliation and Material Balance, Execution Fast Tour QUALITY Balance Index 21

22 Data Reconciliation and Material Balance, Execution Fast Tour Initial Imbalances (Overview) 22

23 Data Reconciliation and Material Balance, Execution Fast Tour Initial Imbalances (Detail) 23

24 SCM SF Analysis Data Reconciliation and Material Balance, Execution Fast Tour Deviations 24

25 SCM SF Raw Data Data Reconciliation and Material Balance, Execution Fast Tour Reviewing the Data

26 Escritorio SF Auditoría Tolerancias Data Reconciliation and Material Balance, Execution Fast Tour Reviewing the Tolerances 26

27 The CORE, the Process Model A PI-AF(SF) model of: Process Flows Flows characterizations Inventories Measurements Sources of data Data processing methods Calculation RULES Balance RULES

28 The CORE, the Process Model

29 The CORE, the ENHANCED Process Model Met. Accounting Rules and Processes Base (SF-AF) Model Reconciled (balanced) values of: Material flows & Composition Inventories & Composition Water:supply-recovery-use- reco se inventory. Contextual reference to: Real time and history of related measurements and lab data + Traceability Op. Accounting Rules and Processes Context (Model) related values of: Program Target Context (Model) related values of: Key consumables Steel Energy Reagents Key asset KPI Availability Use & Data Quality fit for purpose: Values from instruments Values from inventory variation Values from the ERP

30 The System Architecture SCM SF Data Collection Data Pre Filtering i Op Data Processing Data Validation Error Id and Calculation Analysis Results Met Accounting Rules & Processes Op. Accounting Rules & Processes SIGMAFINE PI-AF Metadata ENHANCED MODEL PI LIMS OTHERS

31 The System Architecture Business Systems Total Values Line/Area Values Consumables Production Stats. Avg, Cummulated Process Values Operational KPI Real vs. Program Data Validation Adjustments Reconciliation Aggregation Calculations KPI s calcs Operational Contexts Functional contexts Workflow Inventories Down Times Levels Ore Characteristics Real time Data Lab Data Mine Systems Data Equipment Data Analysis Flows PROCESS

32 The System Architecture Business Systems Total Values Line/Area Values Consumables Production Stats. Avg, Cummulated Process Values Operational KPI Real vs. Program Inventories Down Times Levels Ore Characteristics Real time Data Lab Data Mine Systems Data Equipment Data Analysis Flows PROCESS

33 Met Accounting Implementation Process Model Definition

34 Met Accounting Implementation Process Model Definition

35 Met Accounting Implementation Process Model Definition

36 Met Accounting Implementation Process Model Definition

37 Met Accounting Implementation Process Model Definition

38 Met Accounting Implementation Process Model Definition Execution, validation and publishing procedures

39 Met Accounting Implementation Process Definitions Model Definitions Model Analysis Solvability Redundancies Consistency

40 PROJECT METHODOLOGY REFERENCE Activity Site Responsible Deliverables Kickoff Meeting Customer Site SF - Customer - Scope - Functional Specs. System Platform and Infrastructure Data Gathering Documents Customer Customer - Prepared Infraestructure for the System SF SF - Flowsheet Diagram - Data Gathering Spreadsheets Data Gathering Customer Customer - Complete Data Gathering Spreadsheets Preliminary Model and Redundancy Test Prepare Data for Model Validation Model Validation SF- One / two weeks in customer site for Model adjustments SF - Preliminary Model Customer Customer - Data for Model Validation SF- One/two weeks in customer site for final model adjustments SF - Model validated Model installation Customer Site SF - Customer - Model installed

41 SF in M&M Copper-Moly Conc. Smelter Refinery Leaching SX/EW Codelco-North Codelco-Andina Codelco-Teniente * * * * * * Antofagasta Minerals- MLP * * * Xstrata&Anglo Collahuasi * * * KUCC-Pilot * * GOLD Conc. Leahing Carbon in Column Plant XX (project in progress) Merrill Crowe Smelter * * * * *

42 SF in M&M Xstrata&Anglo Collahuasi Antofagasta Minerals-MLP Fresh water supply, consumptions, water recovery

43 Luis Yacher