Evaluating options to increase production of a copper smelter aisle: A simulation approach

Welgama, Palitha; Mills, R. G. J.; Aboura, Khalid; Struthers, A; Tucker, Diana

doi:10.1177/003754979606700404

Cited by 7 publications

(7 citation statements)

References 6 publications

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“…For example, in a plant where two overhead cranes operate simultaneously on the same rails, the daily output cannot be modeled unless the movement of the cranes is modeled. However, such traffic relies heavily on the coordination between the crane drivers, a set of rules and the large production traffic bellow the cranes (Welgama et al, 1996).…”

Section: Discussionmentioning

confidence: 99%

The need for simulation in complex industrial systems

2012

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We discuss the concept of simulation and its application in the resolution of problems in complex industrial systems. Most problems of serious scale, be it an inventory problem, a production and distribution problem, a management of resources or process improvement, all real world problems require a mix of generic, data algorithmic and ad-hoc solutions making the best of available information. We describe two projects in which analytical solutions were applied or contemplated. the first case study uses linear programming in the optimal allocation of advertising resources by a major internet service provider. the second study, in a series of projects, analyses options for the expansion of the production and distribution network of mining products, as part of a sensitive strategic business review. using the examples, we make the case for the need of simulation in complex industrial problems where analytical solutions may be attempted but where the size and complexity of the problem forces a Monte carlo approach.

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Section: Discussionmentioning

confidence: 99%

The need for simulation in complex industrial systems

2012

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“…An increased throughput with minimum CAPEX requires de-bottlenecking of the smelter and its combined refinery flow-sheet. It is benefitted from feed-forward and feed-backward information of the product streams as well as from the state and performances of the unit processes [7][8], such as off-gas train and its gas handling capacity, or solution purification of the tank house and its limits in, e.g., arsenic elimination from the electrolyte. Sometimes, this approach can be applied from ore mining to refining, and even linked with metal prices [9].…”

Section: Drivers For the Modellingmentioning

confidence: 99%

Modelling copper smelting – the flash smelting plant, process and equipment

Taskinen

Lindberg

Xia

2019

Mineral Processing and Extractive Metallurgy

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The effectivity of present copper smelting technologies have their roots in industrial and laboratoryscale experience accumulated over the past decades. Since early '60s, the tools for improving the processing conditions and smelting vessel design included scale modelling and manual computing of homogeneous multicomponent equilibria. The scale models were isothermal, room temperature constructions where water or air was used as medium and dimensionless numbers ensured scale down and scale up similarities. Today, numerical modelling has opened new insight into the high temperature process modelling where chemical reactions and their heat sinks and sources can be included in the simulations. The utilisation of computational thermodynamics enables a rigorous management of the phase equilibria in industrial multi-components slag-matte-metal systems. This development will be visualised in the framework of various enabling techniques.

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“…Crane speeds, distances, loading and unloading times, waiting times and speed changes when travelling across the aisle were also considered. The situation where only one crane is operating while the other crane undergoes repairs or maintenance was also modelled (Welgama et al, 1996a). All downtimes were analyzed and modelled.…”

Section: The Simulation Modelmentioning

confidence: 99%

“…It was decided in 1997 to shut down the fluidized bed roaster and the reverberatory furnace, and the ISAS-MELT™ furnace throughput was boosted to more than 160 tons/hour of concentrates by the addition of a fourth Peirce-Smith converter (Player, 1998) and a second oxygen plant (Arthur and Hunt, 2005). The simulation described in Welgama et al (1996a) provided support for the major expansion decision of MIM. The simulation study involved a detailed and accurate model capturing the factors affecting production and material handling.…”

Section: Introductionmentioning

confidence: 99%

“…The analysis using the developed software resulted in supporting a decision for a $92M investment to achieve the increase in throughput. Welgama et al (1995), Welgama et al (1996a) and Welgama et al (1996b) describe in details the simulation study jointly conducted by the Commonwealth Scientific and Industrial Research Organisation (CSIRO) and Mount Isa Mines Limited. A detailed and accurate simulation model was developed capturing the factors affecting copper production and materials handling.…”

Section: Introductionmentioning

confidence: 99%

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A Statistical Model for Shutdowns due to Air Quality Control for a Copper Production Decision Support System

Aboura

2015

Organizacija

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Background: In the mid-1990s, a decision support system for copper production was developed for one of the largest mining companies in Australia. The research was conducted by scientists from the largest Australian research center and involved the use of simulation to analyze options to increase production of a copper production facility. Objectives: We describe a statistical model for shutdowns due to air quality control and some of the data analysis conducted during the simulation project. We point to the fact that the simulation was a sophisticated exercise that consisted of many modules and the statistical model for shutdowns was essential for valid simulation runs. Method: The statistical model made use of a full year of data on daily downtimes and used a combination of techniques to generate replications of the data. Results: The study was conducted with a high level of cooperation between the scientists and the mining company. This contributed to the development of accurate estimates for input into a support system with an EXCEL based interface. Conclusion: The environmental conditions affected greatly the operations of the production facility. A good statistical model was essential for the successful simulation and the high budget expansion decision that ensued.

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Evaluating options to increase production of a copper smelter aisle: A simulation approach

Cited by 7 publications

References 6 publications

The need for simulation in complex industrial systems

The need for simulation in complex industrial systems

Modelling copper smelting – the flash smelting plant, process and equipment

A Statistical Model for Shutdowns due to Air Quality Control for a Copper Production Decision Support System

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