Next Generation Software Technologies
using 3D Emulation for the Mining Industry
Rev. 3.0
Page 1
Who Are We ?
Multidiscipline Dynamic Modeling & Simulation
Products and turnkey solutions provider for:
• Naval military sector
• General industry
The products and services cover:
• Process engineering,
• Performance Analysis,
• Real-time Control & Optimization
• and Training Systems
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Our Products Modeling Capabilities
Multidiscipline Dynamic Modeling & Simulation for:
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Liquids
Gases
Ventilation
Electrical generation and distribution
Controls
Propulsion
Cause & Effect and decisional logic
Page 3
Our Products Application Lifecycle
Conceptual
Design
Design
Requirements
Functional
and
Detailed Design
Product
Definition
Page 4
Our Products Application Lifecycle
Conceptual
Design
Analysis
and
Testing
Requirements
Functional
and
Detailed Design
Virtual
Testing
Product
Definition
Performance
Analysis
Validated
Systems
Page 5
Our Products Application Lifecycle
Training
Simulations
Conceptual
Design
Operator
Training
Requirements
Operational
Systems
Functional
and
Detailed Design
Virtual
Testing
Product
Definition
Performance
Analysis
Validated
Systems
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Our Products Application Lifecycle
Re-fit and
upgrades
Conceptual
Design
Real-time Control
& Optimization
Deployable
System
Training
Simulations
Control
and
Optimization
Requirements
Functional
and
Detailed Design
Operational
Systems
Virtual
Testing
Product
Definition
Performance
Analysis
Validated
Systems
Page 7
Mine Ventilation Optimization
“The Business Case”
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Ventilation = 35-50% of operating cost  1 – 30 M$ / year
Need to extract deeper ore bodies
Required energy increases exponentially
Often ventilation equipment is already maxed-out
Energy prices continue to increase
Carbon emission costs may be added to financial statements
Aggressive energy management inevitable to remain
competitive
• No compelling solution was available yet
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Mine Ventilation Optimization
“The Solution”
• Dynamic tracking of diesel machinery
• Ventilation calculation demand for each of the mine work zones
• High fidelity modeling and simulation of the ventilation network
• Calculation of a real time mass balance for the ventilation network
• Control and optimization of air distribution and required electrical energy
• Setpoint optimization for all fans and airflow regulators
• Setpoints sent to the physical control devices via OPC
Expected benefits:
 30 to 50+ % energy savings
 Improved air distribution where needed, when needed
 Enhanced safety
Page 9
Mine Ventilation Optimization
“The Iconics Integration”
A turnkey solution that integrates complementary products
1. Engineering Suite
1. GENESIS 32 4. GENESIS 64
2. OPC Server
2. DataWorX
5. WebHMI
3. BridgeWorX
6. ReportWorX
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Mine Ventilation Optimization
Functional Architecture
All information
interchange
Server
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Mine Ventilation Optimization
Functional Architecture
• Battery-powered wireless mesh network
• Dynamic tracking of machinery
location and operating status
or
Server
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Mine Ventilation Optimization
Functional Architecture
Engineering
Suite
A control system comprising:
• Dynamic ventilation
demand calculation
or
Server
• Physics based high fidelity
ventilation network model
• Regulatory analog and logic
controls
• Air flow optimizer
• Energy optimizer
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Mine Ventilation Optimization
Functional Architecture
Smart P&IDs
Engineering
Suite
• Calculates ventilation
demand from tracking
information
• Model performs a real time
mass balance
• Real-time results for flow,
pressure, velocity and
temperature
or
Server
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Mine Ventilation Optimization
Functional Architecture
Engineering
Suite
Control Schematics
• Real-time analog and logic
control
• Air flow and energy
optimization
or
Server
• Fans and air flow setpoints
sent to PLCs via OPC
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Mine Ventilation Optimization
Functional Architecture
Engineering
Suite
or
Server
Live MS-Excel link to
simulation, controls and
optimizer.
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Mine Ventilation Optimization
Functional Architecture
Engineering
Suite
Dynamic and interactive
performance analysis and tuning.
or
Server
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Mine Ventilation Optimization
Functional Architecture
Engineering
Suite
or
Server
Bi-directional communication to
PLCs and other external systems.
PLCs
Covers communication
redundancy.
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Mine Ventilation Optimization
Functional Architecture
Engineering
Suite
provides the user
interface for surface
operators.
WebHMI provides user
interface to
underground miners.
or
Server
RerportWorX also
provides system
operation, events and
alarm reporting.
PLCs
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Mine Ventilation Optimization
“The Next Generation”
Engineering
Suite
or
Server
PLCs
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Mine Ventilation Optimization
“Smart P&IDs”
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Mine Ventilation Optimization
“Controls and Optimizer”
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Mine Ventilation Optimization
“Excel as an Engineering Aid”
Microsoft Excel dynamic link to the simulation model
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Mine Ventilation Optimization
“Tracking”
Tracking provides machinery
location and operating status
Ventilation demand calculated
from the tracking results
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Mine Ventilation Optimization
“Tracking”
Dynamic demand calculation
based on tracking
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Mine Ventilation Optimization
“Tracking”
Dynamic demand calculation
based on tracking
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Mine Ventilation Optimization
“Control modes”
• Manual; operator sets a fan speed or an air flow regulator opening position,
• Auto-CFM; operator sets a desired CFM flow for a fan or air flow regulator,
• Auto-VOD; optimizer calculates optimal required air flow as per results of
the dynamic tracking.
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Mine Ventilation Optimization
Conclusion
This is more than “Control & Optimization”
 Challenge existing and new design performance through analysis
 Quickly evaluate alternatives
 Test drive a design
 Assist in adequate equipment sizing
 Validate mine expansion as planning tool
 Enable deeper mining with available ventilation resources
This solution is also applicable to other industries!
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