From Material Balance to Met. and Operational Accounting

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1 From Material Balance to Met. and Operational Accounting

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. And 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: what goes in - + = what goes out Inventory variation 0

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 DATA MANAGEMENT MET ACCOUNTING MODEL 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 AGREGATE 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 Minimize N S i = 1 2 ( Raw i - Reconciled i ) Absolute Tolerancei

16 Data Reconciliation and Material Balance, AMIRA reference model Metal Balance RESULTS ANALYSIS ADJUSTMENTS REVIEW GROSS ERROR DETECTION BIAS DETECTION IMBALANCE ANALYSIS Meter y = x meter18 Linear (meter18) Meter 11 SIGMAFINE TOOLS Test1, Test2 statistical parameters for variable deviation evaluation Test3, Test4 statistical parameters for imbalance evaluation Influence determination Meter y = x y = x y = x meter8 Linear (meter8) meter11 Linear (meter11) Linear (meter11)

17 Data Reconciliation and Material Balance, Execution fast tour SCM SF 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-useinventory. 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 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 Agregation 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 Met Accounting Implementation Process Model Definition

33 Met Accounting Implementation Process Model Definition

34 Met Accounting Implementation Process Model Definition Flujo de Información Sistema de Reportabilidad SIP (Ejemplo Genérico) Sistema Control PI SIP Operaciones Procesos Gestión Chancado : Bailey Eléctrico : SCADA PI01: Sistema PI SIP01: Sistema SIP Mediciones Espesadores : Reporte Excel Nombre = IMD_CIMM.xls Niveles y Solidos Espesadores Periodo = Semanal Tipo = IMD Propietario = Lab Metalúrgia Grupo = IMD_LABMET Análisis quimicos Espesadores : Reporte Excel Nombre = aq_diario.xls A. Quim. Espesadores Periodo = Diario Tipo = IMD Propietario = Lab Químico Grupo = IMD_LABQUIM Flujometros Alim. Espesadores Niveles y Solidos Espesadores A. Quim. Espesadores Inventarios Concentradora : Reporte Excel Nombre = Ope_conc.xls Periodo = Diario Tipo = Validador Propietario = Calidad Grupo = CTL_CALIDAD Concentrado Esp. validado Análisis Quimicos TK-301, TK-302, TK-303 : Reporte Excel Nombre = anaquimconc.xls A. Quimicos Periodo = Diario Tipo = IMD Propietario = Lab Químico Grupo = IMD_LABQUIM Tonelajes SAG PI Tonelajes Molienda SAG : Reporte Excel Nombre = tonel_sag12.xls Tonelajes SAG Periodo = Turno Tipo = IMD Propietario = Operación Molienda Grupo = IMD_SAG A. Quimicos, Tonelajes SAG. A.Quimicos Validados, Tonelajes Validados, FCU, FMO. A.Quimicos Validados, Tonelajes Validados, FCU, FMO. Concentrado Esp. validado Prog. Anual Prog. Anual A.Quimicos Validados, Tonelajes Validados, FCU, FMO. Operación Planta : Reporte Excel Nombre = Informe Diario.xls Periodo = Diario Tipo = Validador Propietario = Calidad Grupo = CTL_CALIDAD Programa Producción Anual : Reporte Excel Nombre = prog_p1 Periodo = Anual Tipo = IMD Propietario = Sup. Int. Planificación y Procesos Grupo = Plan_Proc Resultados Operacionales Pta. Concentradora : Reporte Web Nombre = Resumen.xml Periodo = Diario Tipo = Reporte Cumplimiento Programa Anual : Reporte Web Execution, validation and publishing procedures Prog. Anual Nombre = Cumplimiento_v0.xml Periodo = Diario Tipo = Reporte

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

36 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 SF- One / two weeks in customer site for Model adjustments SF - Preliminary Model Prepare Data for Model Validation Customer Customer - Data for Model Validation Model Validation SF- One/two weeks in customer site for final model adjustments SF - Model validated Model installation Customer Site SF - Customer - Model installed

37 and 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 Caserones * * * * * * * * * * WATER * * GOLD Conc. Leaching Carbon in Column Plant XX Merrill Crowe Smelter * * * * *

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

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