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17th
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Vienna,
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Mineral Aug
and 31on Control,
-- Sept
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Processing
17th IFAC
Vienna, Symposium
Austria. Aug 31on Control,
Sept 2, Optimization and Automation in
2016
Mining, Mineral
Vienna, Mineral
Mining,
and
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AugMetal
31 - Sept 2, 2016Available online at www.sciencedirect.com
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Real-Time
Real-Time Simulation
IFAC-PapersOnLine and
49-20 (2016) 061066
Simulation and Control
Control of
of a
a
Real-Time
Real-Time Simulation and Control of a
Real-Time Simulation SAG
Simulation
SAG
SAG
Mill
Mill
Mill
and
and Control
Control of
of a
a
SAG
SAG Mill
Mill
F. Guerrero J. Bouchard
E. Poulin D. Sbarbaro
F. Guerrero J. Bouchard E. Poulin D. Sbarbaro
F. Guerrero J. Bouchard E. Poulin D. Sbarbaro
F.
F. Guerrero
Guerrero J. Bouchard E. Poulin D. Sbarbaro
J. Bouchard E. Poulin D.deSbarbaro
Department of Electrical Engineering, Universidad Concepcion,
Department of Electrical Engineering, Universidad de Concepcion,
Department
Concepcion,
Concepcion,of Electrical
Chile,
Chile, Engineering,
(e-mail:
(e-mail: Universidad
daniel.sbarbaro@udec.cl)
daniel.sbarbaro@udec.cl) de Concepcion,
Department

Department of
ofofElectrical Engineering, Universidad de Concepcion,
Concepcion,
Department
Department
Concepcion, ofElectrical
Mining,
Chile,
Engineering,
Chile, Metallurgical
Mining, Metallurgical
(e-mail:
Universidad
(e-mail: daniel.sbarbaro@udec.cl)
and
and Materials
Materials
daniel.sbarbaro@udec.cl)
deEngineering.
Concepcion,
Engineering.
Concepcion,
Department
Universite
Universite of Chile,
Mining,
Laval, (e-mail:
Metallurgical
Quebec
Laval, Quebec daniel.sbarbaro@udec.cl)
(Quebec),
(Quebec),and Materials
Canada,
Canada, Engineering.
(e-mail:
(e-mail:
Department of Mining, Metallurgical and Materials Engineering.
Department
Universite ofjocelyn.bouchard@gmn.ulaval.cal)
Mining, Metallurgical
Laval, Quebec (Quebec),
jocelyn.bouchard@gmn.ulaval.cal) andCanada,
Materials Engineering.
(e-mail:
Universite
Universite
Department
Laval,
Laval, Quebec
Quebec (Quebec),
(Quebec),
jocelyn.bouchard@gmn.ulaval.cal)
of Electrical Canada,
Canada, (e-mail:
(e-mail:
Department of Electrical and Computer Engineering, Universite
and Computer
jocelyn.bouchard@gmn.ulaval.cal)
Engineering, Universite
Department
Laval,
Laval,
Quebec
Quebec jocelyn.bouchard@gmn.ulaval.cal)
of Electrical
(Quebec),
(Quebec), Canada
Canada and (e-mail:
Computer
(e-mail: Engineering, Universite
eric.poulin@gel.ulaval.ca)
eric.poulin@gel.ulaval.ca)
Department of Electrical and Computer Engineering, Universite
Department
Laval, of Electrical
Quebec (Quebec), Canada and (e-mail:
Computer Engineering, Universite
eric.poulin@gel.ulaval.ca)
Laval,
Laval, Quebec
Quebec (Quebec),
(Quebec), CanadaCanada (e-mail:
(e-mail: eric.poulin@gel.ulaval.ca)
eric.poulin@gel.ulaval.ca)
Abstract:
Abstract: Real-time
Real-time simulation
simulation plays plays an an important
important role role not
not only
only in in the
the design
design and and commis-
commis-
Abstract:
sioning of
sioning of new Real-time
new control simulation
strategies,
control simulation
strategies, but plays
but an
also
also important
in
in training
training the role
the not only
operators
operators in the
before
before design
the actual
the actual and commis-
system
system is
is
Abstract:
Abstract:
sioning
installed. Real-time
Real-time
of There
new
There controlin simulation
are in strategies,
the market but plays
plays an
also
several important
ansimulation
important
in role not
trainingenvironments
simulation the
environments only
role operators
not onlyfor in
in the
before
for carrying design
the design
the actual and
outand commis-
commis-
system
these tasks.is
installed.
sioning of new are
control the market
strategies, several
but also in training the operators carrying
before the out
actual these
system tasks.is
sioning
installed.
However, of
However, There new
There
there control
isare
there isare in
still
still astrategies,
the
need
athe
needmarket
of but
having
of having also
severalmore
more in training
simulation
flexible the operators
environments
environments
flexible environments before
for
that
that carrying
can the
be actual
out
easily
can be easily system
these tasks.
integrated
integrated is
installed.
installed.
However,
with other There
there is
systems are in
in
still
and athe
need
toolsmarket
market
of
such several
several
having
as more simulation
simulation
real-time flexible environments
environments
environments
optimization and for
for
that
advanced carrying
carrying
can be
data out
out
easily these
these
analysis. tasks.
tasks.
integrated
In this
with otherthere
However, systems
is and tools such as real-time optimization and advanced data analysis. In this
However,
with
work,other
work, there
several
several is still
systems
standard
standardanda
still need
a tools
tools
of
of having
need such
tools such having
as
as
more
more flexible
real-time
Simulink
Simulink

flexible
R

R
environments
optimization
/Simulink
/Simulink

environments
R ,and
R

, OPC
OPC
that
that
advanced
toolbox,
toolbox,
can
candata be
be easily
easily
analysis.
RSLogix
RSLogix
integrated
integrated
5000,
5000, In this
and
and
with
with other
work,other
several
FactoryTalk systems

systems
R standard
R and
are integratedtools
and tools
integrated such
tools such as
to simulate real-time
as real-time
Simulink
simulate 
Roptimization
a control strategy
optimization
/Simulink
control R and
,and
forOPC advanced
a advanced
SAG data
mill data
toolbox, analysis.
analysis.
RSLogix
designed to5000,
keepIn
In this
this
and
the
FactoryTalk
work, several  are to
R standard tools such as Simulink
a 
R strategy
R /Simulink
R for
 a SAG mill designed
R , OPC toolbox, RSLogix 5000, and
to keep the
work,
mill
mill several
FactoryTalk
operating
operating  standard
are tools
integrated such
to as Simulink
simulate a /Simulink
control strategy ,
forOPCa
R in the stable region by manipulating the fresh ore feed. The implementation of
in the stable region by manipulating the fresh ore SAG toolbox,
feed. mill
The RSLogix
designed to
implementation5000,
keep and
the
of
FactoryTalk
FactoryTalk
mill
this operating
strategy R are integrated to simulate a control strategy for a SAG mill designed to keep the
isare
in integrated
the
based stable
on to
region
standard simulate
by a control
manipulating
control blocks strategy
the
available for
fresh
in a
ore
the SAGfeed. mill
The
ControlLogix designed to
implementation keep
Programmable the
of
this
mill strategy
operating isinbased
the on
stablestandard
region control
by blocks
manipulating available
the in
fresh the
ore ControlLogix
feed. The Programmable
implementation of
mill
this
Logic
Logic operating
strategy
Controllers
Controllersisin the
based stable
(PLCs).
(PLCs).on region
standard
Experimental
Experimental by manipulating
control blocks
results
results show
show the
available
the fresh
in ore
the
effectiveness
the effectiveness feed. The
ControlLogix
of the implementation
Programmable
proposed
of the proposed approach
approach of
this
this
Logic
to strategy
strategy
Controllers
integrate is
is based
based
standard(PLCs).on
on standard
standard
tools,Experimental
and control
control
open new blocks
blocks
results available
available
show
possibilitiesthe in
in the
the
effectiveness
for further ControlLogix
ControlLogix
of the
developments Programmable
Programmable
proposed in approach
the design
to
Logicintegrate standard
Controllers (PLCs).tools, and open
Experimental new possibilities
results show the for further
effectiveness developments
of in the design
Logic
to
of
of Controllers
integrate
advanced
advanced standard(PLCs).
monitoring
monitoring tools,
and
andExperimental
and
control
controlopen newresults
strategies
strategies show
possibilities
for
for thefor
industrial
industrialeffectiveness
further
processes.
processes. of thethe proposed
developments proposed in the approach
approach
design
to
to integrate standard
integrate monitoring
of advanced standard tools,tools,
and andand
controlopen
open new possibilities
new possibilities
strategies for further
for further
for industrial processes. developments
developments in the design
in the design
of
of advanced
advanced monitoring
monitoring and
and control
control strategies
strategies for
for industrial
industrial processes.
processes.
2016, 1. IFAC (International
1. INTRODUCTION Federation of Automatic Control) Hosting
operability by Elsevier Ltd. All rights reserved.
INTRODUCTION operability (HAZOP)
(HAZOP) analysis, analysis, and and on-line
on-line optimization
optimization
1. INTRODUCTION operability
[Parthasarathi
[Parthasarathi (HAZOP)
et
et al.,
al., analysis,
2009].
2009]. A
A and
summary
summary on-lineof of optimization
the
the current
current
1. INTRODUCTION
1. INTRODUCTION operability
operability (HAZOP)
(HAZOP) analysis,
analysis, and
and on-line
on-line optimization
optimization
The interest of using analytical models to support
The interest of using analytical models to support process alternatives process [Parthasarathi
alternatives for
for etthe
the al., 2009].
development
development A summary
of
of industrial
industrial of the current
plant
plant sim-
sim-
The interest of using analytical models to support process [Parthasarathi
[Parthasarathi
alternatives
ulators is for
presentedet
etthe al.,
al., 2009].
2009].
development
in Carrasco A
A summary
summary
of
and industrial
Dormido of
of the
the current
current
plant
[2006]. sim-
control
control developments
developments for mineral
for mineral processing
processing plants
plants goes
goes ulators is presented in Carrasco and Dormido [2006].
The
The interest
interest
control of
of
developmentsusing
using analytical
analytical
for mineral models
models to
to
processing support
supportplants process
process
goes alternatives
alternatives
ulators is for
for
presented the
the development
development
in Carrasco of
of
and industrial
industrial
Dormido plant
plant
[2006]. sim-
sim-
back to the beginning
back to developments
the beginning of of the
the 1970s with
1970sprocessing the
with the early early work
work of
of Belanger
control
control developments for
for mineral
mineral processing plants
plants goes
goes ulators is
Belangeris et
ulators et al.
presented[2010] in explain
al. [2010]inexplain
presented Carrasco
Carrasco how
how and
and simulation
Dormido
simulation
Dormido of
of electrical
[2006].
electrical
[2006].
back to
Scrimgeour
Scrimgeour the beginning
et
et al. [1970] ofon
al. [1970]ofonthethe 1970s
flotation
flotation with the
simulation.
simulation. early
A work
plethora
A plethora of
back
back to
to the
Scrimgeour
of the et
academic beginning
beginning
al. [1970]ofonthe
developments 1970s with
1970s simulation.
flotation
followed with
over the
the
the early
early
years,work
work
A plethora of Belanger
of
ever-
systems
systems
Belanger
et al.been
have
have
et
[2010]
been explain
used
used how simulation
extensively
extensively for
for decades
decades of electrical
in
in engi-
engi-
of academic
Scrimgeour etdevelopments
al. [1970] on followed
flotation over the
simulation. years,
A ever-
plethora Belanger
systems
neering.
neering. et al.
have
They
They
[2010]
al.been
[2010]
also
also
explain
explain
used
emphasize
emphasize
how
how
extensively
that
that
simulation
simulation
for decades
real-time
real-time
of electrical
ofsimulation
electrical
in engi-
simulation
Scrimgeour
of academic
growing et al. [1970]
developments
computational on flotation
followed
capabilities simulation.
over the
constantly A plethora
years, ever-
enabling systems have been used extensively for decades in
growing
of academic computational
developments capabilities
followed constantly
over the enabling
years, ever- systems
neering.
environments
environments have been
also used
Theyallowing
allowing emphasize extensively
aa virtual
virtual that
plant forto decades
plantreal-time
to be
be connected in engi-
connected engi-
simulation to
to
of academic
growing
new
new possibilities, developments
computational
possibilities, and more
and more followed
capabilities over
sophistication.
sophistication. the
constantly
In years,
the last
In the enabling ever-
enabling two
last two neering.neering. They also emphasize that real-time simulation
growing computational capabilities constantly environments
either
either a
a They
simulated
simulated also
allowing or
oremphasize
a virtual
physical
physical that
plant
controller,
controller,real-time
to be
are
are simulation
connected
particularly
particularly to
growing
new
decades,
decades, computational
possibilities,
the and
programming
the programming morecapabilities
sophistication.
platform constantly
In the
Matlab/Simulink
platform Matlab/Simulink enabling
last two

R
 environments allowing aadesign
virtual plant to be connected to
new possibilities, and more sophistication. In the last R
two environments
either a
interesting
interesting allowing
simulated
during
during the or
the virtual
physical
design andandplant
controller, to be
are
commissioning
commissioning connected
particularly
phases
phasesto
new possibilities,
decades,
progressively
progressively and more sophistication.
the programming
overshadowed
overshadowed platform
all
all other
other In the last lan-
Matlab/Simulink
programming
programming two

R
lan- either a simulated or physical controller, are particularly
decades, the programming platform Matlab/Simulink 
R either
of
of a
a a
interesting simulated
project
project during
as
as they
theyor
the physical
design
enable
enable controller,
and
powerful
powerful are
commissioning
early
early particularly
testing
testing phases
and
and
decades,in
guages in the
progressively programming
overshadowed
universities and platform
all other
and research Matlab/Simulink
programming
centres, but
but specialized 
lan- interesting during the design and
and commissioning phases
R
guages
progressively universities
overshadowed research
all centres,
other programming specializedlan- interesting
of a project
debugging during
as they
capabilities. the enabledesign
This powerful commissioning
notwithstanding, phases
early applications
testing and
progressively
guages in
off-the-shelf overshadowed
universities
toolkits and
started all
research other
emerging programming
centres,
more but specialized
recently forlan-
in- debugging
of a project capabilities.
as they This
enable notwithstanding,
powerful early applications
testing and
off-the-shelf
guages in toolkits started
universities and emerging
research more but
centres, recently for in- of
specialized in a
debuggingproject
mineral as they
capabilities.
processing enable
This
are powerful
notwithstanding,
still rather early
scarce, testing
applications
but and
Nees
guages
dustrial
dustrial inapplications,
off-the-shelf universities
applications, and
toolkits started
with
with research
emerging
companies
companies centres,
more
like
like but
recently
Outotec
Outotec for in- in
specialized
[Roine
[Roine
mineralcapabilities.
debugging processing This are still rather scarce,
notwithstanding, but Nees
applications
off-the-shelf toolkits started emerging more recently for in- debugging
in
and mineral
Gamarano capabilities.
processing
[2011] This
are
clearly notwithstanding,
still rather
demonstrated scarce, applications
the but Nees
potential
off-the-shelf
dustrial
et al.,
al., 2011], toolkits
applications,
and
and Andritz started
with emerging more
companies
[Parthasarathi like
et recently
Outotec
et al., for
2009,[Roine
2009, Schugin- and in Gamarano [2011] clearly demonstrated the butpotential
et
dustrial
dustrial
2011],
applications,
applications,
Andritzwith
with
[Parthasarathi
companies
companies like
like
al.,
Outotec
Outotec
Schug
[Roine
[Roine for mineral
in
and
for mineral
Gamarano
risk
risk
processing
processing
mitigation
mitigation [2011]with
are
the still
are
withclearlythe still
example
example
rather
rather
demonstrated scarce,
scarce,
of Newmont
of Newmontthe but Nees
Nees
potential
Mining
Mining
et
et al.,
al., 2011],
2012].
al.,2011], and
2012].and These
TheseAndritz [Parthasarathi
simulation
simulation platforms
platforms et al., 2009,
typically
typically Schug
inte-
inte- and and Gamarano [2011] clearly demonstrated the potential
et al., Andritz [Parthasarathi et al., 2009, Schug for Gamarano
risk
the mitigation
Conga [2011]with
project. clearly
the
The demonstrated
example
plant of Newmont
real-time the potential
Mining
simulation
et al.,
grate a2011],
al.,a
grate 2012]. and
graphical
graphicalTheseAndritz
programming[Parthasarathi
simulation
programming platforms
environment,
environment, et al., 2009,aa Schug
typically
and
and set
set of and
inte-
of for
for
themitigation
risk
risk
Conga project.
mitigation with
with
Theexample
the
the
plant real-time
example of
of Newmont
Newmont
simulation
Mining
Mining
et
et al.,
al., 2012].
2012]. These
These simulation
simulation platforms
platforms typically
typically inte-
inte- and
model,
model, theprogrammed
Conga project.
programmed in
in the
the The plant IDEAS
platform
platform real-time
IDEAS simulation
(Andritz)
(Andritz) was
was
grate a graphical
configurable
configurable programming
preprogrammed
preprogrammed environment,
unmodifiable
unmodifiable unit
unit and a set
operation
operation of and the Conga project. The plant real-time simulation
grate a graphical programming environment, and a set of and
model, the
developed
developed Conga
programmed
and usedproject.
in the
throughout
and used throughout The plant
platform the real-time
IDEAS
project
the IDEAS life
project (Andritz) simulation
(Andritz)
life cycle, was
cycle, i.e.
i.e.
grate
models.
models. a graphical
configurable programming
preprogrammed environment,
unmodifiable unit and a set
operation of model, programmed in the platform was
model, programmed invalidation
the platform IDEAS (Andritz) was
configurable
configurable
models. preprogrammed unmodifiable unit operation developed and used throughout the project life cycle, i.e.
preprogrammed unmodifiable unit operation developed
for
for P&ID
P&ID and
and
and used
design
design throughout
validation the
(phase
(phase project
1),
1), life
control
control cycle,
system
system
i.e.
The
The development
development of
models.
models. of dynamic
dynamic simulation
simulation environments
environments in in developed
for P&ID
testing
testing
for P&ID
and design
and
(phase
(phase
and
used
2),
2),
design
and
and throughout
validation
operator
operator training
validation
the project
(phase
training
(phase
1),
(phase
1),
life 3).
control
(phase
control
cycle,
3). i.e.
system
system
The development
mineral
mineral processing
processingofhasof
hasdynamic
mainly simulation
been
mainlysimulation justified
been justified environments
by advanced
by advanced in for P&ID
testing and
(phase design
2), and validation
operator (phase
training 1), control
(phase 3). system
The
The development
development
mineral
process
process processing
control dynamic
ofhas
control purposes, dynamic
purposes, i.e. simulation
mainly
i.e. been justified
designing
designing
environments
environments
by advanced
control
control systems
systems in Proprietary
in testing
Proprietary
testing (phase
(phase simulation
2),
2), and
simulationand operatorenvironments
environments
operator training
training such
such as
as IDEAS
(phase
(phase 3).
IDEAS
3). can
can
mineral
mineral processing
processing has
has mainly
mainly been
been justified
justified by
by advanced
advanced Proprietary
be
be configured
configured simulation
relatively
relatively environments
easily
easily as
as only
only such
the
the as IDEAS
parameters
parameters canof
of
process
allowing control
allowing increased purposes,
increased productivity, i.e. designing
productivity, improved control
improved product systems
product qual- qual- Proprietary simulation environments such as IDEAS can
process control purposes, i.e. designing control systems Proprietary
be
the
the configured
unit simulation
operation
unit operation relatively
models
models environments
easily
are as only
required
are required such
the
to as
be
to be IDEAS
parameters
provided
provided by canof
by
process
allowing
ity,
ity, and control
increased
reduced
and increased purposes,
reduced power i.e.
productivity,
power designing
consumption
consumption improved control
product
[Sbarbaro,
[Sbarbaro, systems
qual-
2010].
2010]. be configured relatively easily as only the parameters of
allowing productivity, improved product qual- be
the
the configured
unit
user. operation
On
user.operation relatively
the
On the other models
other easily
are
hand,
hand, as
the only
required model
the model the
to beparameters
provided
structures
structures of
by
are
are
allowing
ity,
New
New and increased
reduced
applications
applications productivity,
power
nowadays
nowadays consumption
aim
aim improved
at
at product
[Sbarbaro,
addressing
addressing a
a qual-
2010].
much
much the unit models are required to be provided by
ity, and reduced power consumption [Sbarbaro, the unit
user.
predeterminedoperation
On the
and models
other
cannot are
hand,
be required
the
modified. model to
This be provided
structures
could be by
are
lim-
ity,
New and
broader reduced
applications
range of power
nowadays
of engineering consumption
aim [Sbarbaro,
at addressing
issues, such as a 2010].
as equipment much predetermined
2010]. the user. On andother cannothand, be modified. Thisstructures
could be lim-
broader
New range
applications engineering
nowadays issues,
aim at such
addressing equipment
aa much the
iting
iting user.
predetermined
for
for On the
advanced
advanced the other
cannothand,
andapplications
applications in
in
the
the
be modified.
which
which
model
model This structures
aa fine
fine could
and are
are
be lim-
and detailed
detailed
New
broader
sizing,
sizing, applications
range
commissioning
commissioningof nowadays
engineering
of
of aim
control
control at
issues, addressing
such
programs,
programs, as equipment
development
developmentmuch predetermined and cannot be modified. This could be lim-
broader range of engineering issues, such as equipment predetermined
iting for
understanding
understandingadvanced and
of the
of the cannot
applications
process be modified.
in which
behavior
process behavior isThis
a fine
needed.
is needed. could
and be lim-
detailed
Problems
Problems
broader
sizing,
of rangeprocedures,
commissioning
operating of engineering
of control issues,
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Copyright 2016
2016 IFAC
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justifies the need for more flexible open source simulation
environments.
The integration of heterogeneous hardware and software
is a challenging task. Fortunately, the OPC (Open Plat-
form Communications) technology was developed in or-
der to ease the integration of the different components.
OPC is an open hardware and software interface standard
using Client/Server models based on COM (Component
Object Model)/DCOM (Distributed Component Object
Model). This general standard supports the development
of network distributed applications as well as applications
integrating different software platforms. There are many
applications illustrating the integration of control systems
and simulation environments for simple systems. For in-
stance, Mahmoud et al. [2015] present the use of OPC
technology as a cost effective and flexible research tool
based on Matlab R
and Labview R
for the development
and testing of advanced process control (APC) techniques
in university research. Lieping et al. [2007] describe an
application integrating Matlab R
and a S7-300 PLC. More
complex applications are described by Santos et al. [2005].
In addition, the problems concerning real-time data inter-
change and synchronization are also addressed. Lu et al.
[2014] developed and implemented NEUSimMill, a real-
time ball mill grinding circuit simulator, for testing and
verification of real-time control system. In this work, a
methodology for the development of distributed process
simulation using OPC is presented.
The case of semi-autogenous grinding (SAG) mill circuit
control discussed in this paper provides a good example
of an application in which an open source simulation
platform can be required as models for this unit op-
eration in proprietary codes are generally rudimentary.
Section 2 describes the software-in-the-loop environment
used which integrates a Matlab/Simulink R model with
standard tools such as an industrial control platform,
and human machine interface. A SAG mill control system
implementation is presented in Section 3. The discussion
emphasizes on the SAG mill simulation model, and pro-
posed control strategy.
2. REAL-TIME SIMULATION ENVIRONMENT
The real-time environment is based on standard tools
available in the market and widely used in the academia
and industry. The real-time integration of the simulator
with an industrial control system is via OPC. The envi-
ronment developed in this work is depicted in Figure 1.
The four main components are:
Simulation environment. It provides tools for building
models of circuits using a set of standard models of
process equipment and instrumentation. The models
are encapsulated in blocks and an intuitive graphical
interface is used to connect the different components
of the circuit. All the parameters of the models are
defined by a dialog box associated to each one of
them, the actual model equations being transparent
to the user. The connection of blocks represent the
flow of material and energy between the different
pieces of equipment, thus providing a very intuitive
configuration environment that allows laying out cir-
cuits like a piping and instrumentation diagram. This
66
feature, as it has been pointed out by Meciner et al.
[1992], is essential to have the acceptance of the
process and control design engineers, and translate
into practical applications by plant personnel. In this
work, the Simulink R
block diagram simulation en-
vironment has been selected. It provides a graphical
editor, customizable block libraries, and solvers for
modeling and simulation of dynamic systems. The
simulator is integrated with Matlab R
, enabling the
user to incorporate algorithms into models and export
simulation results for further analysis.
Communication interface. The integration of the sim-
ulator and the control system is carried out using
RSLinxTM and OPC ToolboxTM . This toolbox en-
ables reading, writing, and logging OPC data from
applications that conform to the OPC Foundation
Data Access standard. The OPC Toolbox provides
three options to implement an OPC Data Acces
Client:
1. Execute all OPC Toolbox functions directly from
the Matlab R
command line or incorporate them
into the Matlab R
applications.
2. Use the graphical user interface (GUI) to connect
OPC servers, create and configure OPC Toolbox
objects, and read, write, and log data.
3. Use the Simulink Blockset library to read and
write data to and from the OPC server while
simulating a system.
The Simulink R
OPC toolbox offers a configuration
block to specify the OPC clients used in the model, to
define the behavior for OPC errors and events and to
set the real-time behavior. During the simulation, the
model is executed in pseudo real-time, matching the
system clock as closely as possible by automatically
slowing down the simulation. The block parameters
can also be configured so that the simulation runs
more slowly than the system clock. It must be em-
phasized that the real-time control settings do not
guarantee real-time behavior. If the model runs slower
than real-time, a pseudo real-time latency violation
error occurs. It is possible to control how Simulink R
responds to a pseudo real-time latency violation by
using the settings in the Error control panel. The
pseudo real-time latency can be monitored by select-
ing the option Show pseudo real-time latency port.
Pseudo real-time latency is the time spent waiting
for the system clock during each step. If this value
is negative, the simulation runs slower than real-
time and the Simulink R
action is determined in the
Pseudo real-time violation setting.
Once a group object containing item objects is cre-
ated, it is possible to read from or write to an individ-
ual item or all the items in the group simultaneously.
In Matlab R
, read and write operations can occur
either synchronously (Matlab R
execution is blocked
until the operation is complete) or asynchronously
(Matlab R
can continue processing while the opera-
tion is in progress). In Simulink R
, the read and write
blocks retrieve and transmit data synchronously or
asynchronously to and from the OPC server. The
blocks contain a client manager in order to specify
and manage the OPC server, select items and define
block sample times.
 IFAC MMM 2016
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Control environment. In practice, the lower level of WATER FT

01

the control hierarchy is often implemented in PLCs. SUPPLY

V-01

Modern PLCs can be programmed using a wide range M

Ore fresh feed

WT

of languages such as: ladder logic, functional block M-02 02

diagrams, sequential flow charts and structured text. OVERSIZED

These languages make it possible to implement very ST

01
WT
03
VIBRATORY SCREEN
TO CONE CRUSHER

complex control algorithms. In this work, the im- WT

01 M

JT
M-01 M M-03

plementation of the control strategy is carried out 01 M

M-04
WT
04
WATER
SUPPLY
FT
02

directly in a ControlLogix PLC. The control envi- WT

V-02

SUMP

ronment is usually part of the control system and 04

AT
01

provides tools for control configuration and debug- FT

03

ging. RSLogix5000 is the programming environment M

P-01
UNDERSIZED VIBRATORY
SCREEN TO
HYDROCYCLONE

for Allen-Bradley PLCs providing flexibility by means

Fig. 2. Simulated SAG mill open circuit.
of easy-to-use editing features and a set of diagnostic
and troubleshooting tools. This software is an IEC- where m and f are vectors which elements represent the
1131-compliant ladder logic programming package mass of ore in each particle size class for the grinding
and runs on Microsoft Windows R
operating systems. chamber, and the feed rate of ore in each particle size class
Human Machine Interface (HMI). The HMI is a respectively. C is a diagonal classification matrix which
supervisory-level application for monitoring and con- elements are defined as [Magne et al., 1995]
trolling the process. It provides a comprehensive set Ci = 1 (c1 i + c2 i ) (2)
of tools to build accurate pictures of the opera-
tions, meeting the requirements of multiple stakehold- where
ers including engineering, maintenance, operations, 1
c1 i =   (3)
and production Information Technology (IT). In this xi
work, FactoryTalk R
View Site Edition (SE) is used. 1+ d50
This tool has a robust and reliable functionality to
set-up the HMIs for operators as well as control en- and  
gineers. k1 1 k
c2 i = (xi M ) exp (xi M ) 1 (4)

Control xi is the average dimension of the ith particle size class,

HMI Congura'on and d50 represents the dimension of particles having 50%
chance of passing the discharge grid. Parameters and M
are empirical functions of the solids fraction by weight (s)
inside the grinding chamber, i.e.
RSlogix5000
Factory Talk RSlinx = k2 exp (13.12 ln (s) 6.61) (5)
M = k3 exp (16.53 ln (s) + 5.54) (6)
Ethernet
k1 , k2 , k3 , and (0 < 1 ) are parameters requiring to
be calibrated.
OPC Toolbox
Matlab/Simulink p is a vector which elements (pi ) are the discharge rate of
ore in each particle size class. Assuming a perfect mixture,
m
p=p (7)
Hm
PLC Simula'on
Fig. 1. General structure of a real-time simulation envi- where 
ronment. p= pi = k4 m (8)

Hm is the ore hold-up in the grinding chamber, and k4 , an

3. REAL-TIME SIMULATION AND CONTROL OF A
empirical parameter requiring to be calibrated.
SAG MILL
p is a vector which elements represent the rate of pro-
The open source Matlab/Simulink R simulation platform, duction of ground ore in each particle size class. The block
a.k.a. the comminution toolbox, was developed at Univer- diagram of the grinding process shown in Figure 3 depicts
sidad de Concepcion in Chile and previously presented by the relationship between f , p, and p .
Sbarbaro [2010]. The simulated model used in the case
D is a lower triangular matrix defined as
study is a SAG mill open circuit composed of an ore feeder,
water control valve, and mill depicted in Figure 2. Mp 1
D= R KR (9)
Hm
The SAG mill model is based on a differential equation
describing the mass balance of ore in the grinding chamber where the mill power draw (Mp ) is given by [Austin, 1990]
dm(t) Hm + W + Wb
= f (t) + C p (t) p(t) D m(t) (1) Mp = k5 D2.5 L (1 AJ) f () (10)
dt Vm

67
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f p* p in order to avoid integral wind-up problems. In this way,

+
Grinding Classification
K C
C p*
Fig. 3. Block diagram of the grinding process.
as a function of the mill diameter (D), length (L), internal
volume (Vp ), volumetric fraction occupied by the charge
(ore, water and grinding media) (J), and mass of grinding
media (Wb ). f () is a function of the rotating speed
expressed as a fraction of the critical speed () and defined
by Austin [1990]. k5 and A are empirical parameters
requiring to be calibrated.
K is a diagonal matrix which elements Ki represent the
specific grinding rate, i.e. the production rate of particles
finer than size fraction i. R is a unitary lower triangular
matrix.
Figure 4 provides a screenshot of the simulation diagram
and the OPC interface in Matlab/Simulink R
. This dia-
gram also shows additional components such as: valves, a
sump, a screen and mixing blocks. The OPC blocks are
depicted in green.
when the controllers are switched from one controller to
the other, no transients are produced [Glattfelder and
Schaufelberger, 2003].
As depicted in Figure 5 additional control loops are
required to control the ratio between water and fresh ore
feedrate, the density and the sumps level. It must also be
emphasized that both the power draw and load set points
must be selected judiciously (i.e. account for liner wear,
changes in calibration or drift in measurements) to ensure
best throughput and prevent overloading.
3.2 HMI
A simple Human Machine Interface was configured using
FactoryTalkR
. The main display, depicted in Figure 6,
shows the process diagram and control loops. The variables
are updated in real-time every second. In addition, the
user can access trends of the main variables and control
configurations from this page.

3.1 Control strategy

One of the main objectives of any SAG mill control

strategy is to manage the load in the mill by adjusting the
ore feed rate and/or manipulating the rotational speed
of the mill. The load is measured by using load cells,
which are calibrated to measure the total weight of water,
grinding media (balls) and ore in the mill, but not the
weight of the mill itself. In many SAG mills, oil pressure
is also used to provide an indirect measurement of the
mill load. It is commonly assumed that SAG mill control
can only be successfully accomplished using advanced
control methods such as model predictive control and Fig. 6. Human Machine Interface.
expert systems. In contrast to these advanced control
approaches, control strategies based on standard control 3.3 Experimental results
blocks available at the PLC level can also be very effective
for stabilizing purposes. In this work, a simple override
The model described in section 3 was calibrated using
control considering measurements of the mill power draw
data of an industrial SAG mill having a diameter of 36
and charge is implemented in a ControlLogix PLC. This
f t and a length of 16 f t. The main operational variables
control strategy has been in operation for more than
are: ore feed rate: 1500-1600 tph, mineral density: 3000
eight years in a large variable-speed SAG mill at MMGs
kg/m3 , pulp density inside the SAG mill: 1875 kg/m3 ,
Century Zinc operation in Australia and controls the mill
percentage of solids inside the mill: 70%, percentage of
with minimal operator involvement over 95% of the time
balls by volume: 12 18%, and product size distributions
[Thornton et al., 2005].
expressed in terms of P50: 1.5-2.5 in, power draw : 10500-
In order to control the load of the SAG mill and prevent 13000 kW (normal operation: 12500 kW ).
overloading a selector based strategy, must be designed.
The configuration of the control strategy was carried
Selector blocks are used in four basic areas of application:
out using standard blocks available in RSLogix 5000. As
equipment protection (override control), auctioneering, re-
shown in Figure 7, the output of the selector block Low-
dundant instrumentation and nonlinear control functions.
select must be connected to the CVoverride port of the
In SAG mill applications, the selector is used to keep
PIDE block. This configuration enables the controllers to
the power draw within the range in which overloading is
track the current control output, thus avoiding the wind-
prevented. In order to implement this constrained control
up problem associated to the controller which was not
system a min selector choses the lowest feed rate set-point
selected.
from either the load or power controller. Under normal
operation, mill load is controlled, and the power controller In order to illustrate the strategy, two simulation scenarios
will only act if the power draw constraint is violated. It is were considered. The first one considers variations in the
essential to reset the integration error of the PID controller mill speed as seen in Figure 8. As the mill speed increases,

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Fig. 4. Simulink simulation model and OPC interfaces.

FF R
01
FIC
01
WATER FT
01
SUPPLY

V-01

Ore fresh feed

M
WT
M-02 02

WIC
02

OVERSIZED
SP_LOAD ST VIBRATORY SCREEN
01
WT TO CONE CRUSHER
03
WIC WT M-01 AIC SP_%SOL
< 01 01 SIC M M-03
M
01 01
JT
01 M WATER
JIC SP_POWER SP_SPEED WT SUPPLY
01 M-04 04 FT
V-02 02

WT LIC SP_LEVEL
SUMP 04 01

AT
01

FT
03
M UNDERSIZED VIBRATORY
P-01 SCREEN TO
HYDROCYCLONE

Fig. 5. Control strategy.

the controller starts increasing the ore feed rate until the Results of this work open the possibility of expanding both
mill reaches its maximum load. Then if the mill speed the process models and control strategies to address com-
is decreased, the controller decreases the ore feed rate in plex operational scenarios. In addition, it also represents
order to maintain the mill operating at the set-point of the an excellent tool for bridging the gap between university
power draw. The second scenario illustrates the effect of research and industrial practice.
step changes in the ball charge in the mill. The controller
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IFAC MMM 2016
Vienna, Austria. Aug 31 - Sept 2, 2016
66 F. Guerrero et al. / IFAC-PapersOnLine 49-20 (2016) 061066

WIC_01_PIDE

PIDE

Mill weight [Ton]

...
!

Mill Power [Kw]

Enhanced PID
BOR_02 499.4777 1650.4833
WT_01 PV CVEU WIC_01_CV !
BOR ... 82.52416
SPProg CV WIC_01_CV_ref
Boolean Or 500.0
SPOper SP WIC_01_SP 1-C3 1-C3
0 0 71.42857
WIC_02_AM In1 Out CVInitReq SPPercent 1-C6
0 1650.7994 71.31765
WIC_02_RL In2 WIC_02_SP CVInitValue PVPercent
0.77645874
CVProg E
1
CVOverride ProgOper
0
CVPrevious Auto
0 0
AlwaysHigh CVSetPrevious Manual
0 1
windupH_WIC_02 WindupHIn Override
0 0
windupL_WIC_02 WindupLIn CVOverrideInv

Ore Flowrate [TPH]

PVTracking
GRT_01 1
1 ProgProgReq
GRT ...
ProgOperReq
82.52416 Greater Than (A>B)
WIC_01_CV_ref ProgAutoReq
1
1-F1 SourceA Dest ProgManualReq
82.54333
JIC_01_CV_ref SourceB ProgOverrideReq

1-F4 AutotuneTag ?
Low_Select

ESEL ...

82.52416 Enhanced Select

WIC_01_CV_ref
82.51357
1-F1 In1 Out
82.54333
JIC_01_CV_ref In2

1-F4
JIC_01_PIDE

PIDE ...

Enhanced PID
BOR_03 12482.747 1650.8666
JT_01 PV CVEU JIC_01_CV
BOR 82.54333

Ball [%]
...
SPProg CV JIC_01_CV_ref
Boolean Or 12500.0
SPOper SP JIC_01_SP 1-C4 1-C5
0 0 17.138672
WIC_02_AM In1 Out CVInitReq E 1-C3
0 1650.7994 1
WIC_02_RL In2 WIC_02_SP CVInitValue ProgOper
0
CVProg CasRat
1
CVOverride Auto
0
CVPrevious Manual
0 0
AlwaysOn CVSetPrevious Override
0
windupH_WIC_02 WindupHIn

windupL_WIC_02
0

1
WindupLIn Time [min]
1 ProgProgReq
GRT_02

GRT ...
ProgOperReq Fig. 9. Override Control under step changes in the ball
ProgAutoReq

JIC_01_CV_ref

1-F4
82.54333 Greater Than (A>B)

SourceA Dest
0
ProgManualReq

ProgOverrideReq
charge.
82.52416
WIC_01_CV_ref SourceB AutotuneTag ?

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