Simulation modeling of a section segment in the processing of ferruginous quartzites

Abstract

In order to improve mineral separation efficiency, new adaptive process monitoring, predicting, and management systems are required. These may be developed through the creation of digital twins of respective processes, stages, and plants. Simulation models are a special type of mathematical models that reproduce the behavior of actual systems in time over a wide range of parameter values. The authors have developed a simulation model of a section segment in the processing of ferruginous quartzites and implemented it in the form of a computer application. The results of pilot tests conducted at section No. 9 of the crushing and processing plant of JSC «Olcon» were used as the initial data for its development. The objective was to predict distribution characteristics for the design size class (–0.071 mm) by process stages when producing magnetite concentrate. The paper presents the identified dependencies between process indicators of distributed mass flows under cyclic loads, the results of statistical processing of the sampling data, and their comparison with the simulation results. The example of modeling the classification and screening processes is used to demonstrate the feasibility of rapidly predicting process efficiency using the Hancock–Luiken criterion. It has been shown that the model may be paired with the enterprise monitoring system, the probability of deviation from the specified conditions may be identified for each section, step-by-step predictions of process indicators and decision-making recommendations may be issued, and direct equipment operation via the automated control system may be performed. It is assumed that the model will be complemented with functions to record distribution of the product mineral composition for each processing operation.