Browsing by Author "Ersayin, Salih"

Now showing 1 - 9 of 9

Concentrator Modeling Database Development and Simulation of Ispat Inland Plant
(University of Minnesota Duluth, 2003-09-05) Ersayin, Salih
The Ispat Inland plant processes two blends of ore during different time periods throughout the year. Although these two blends have mineralogical differences, they go through the same process. The major difference in the process becomes fineness of grind required to achieve desired level of liberation, which is in tum controlled by the rod mill feed rate. This created a unique opportunity for modeling the effect of mineralogy on separation equipment and measuring reliability of the simulator in predicting perfonnance of non-concentration equipment, such as hydrocyclones and fine screens, under different operating and feed conditions. While performance of concentration devices including magnetic separator, hydroseparator and flotation banks was expected to show dependence on variation in mineralogy, particularly on liberation size, performance of classification and screening devices would be largely independent of the liberation characteristics. Therefore, the models were expected to reasonably simulate the performance of these devices for a given blend when plant data from the other blend was available. On the other hand, performance of grinding mills is mostly governed by the grindability characteristics of a given ore type. Differences in mineralogy may or may not have significant effect on their performance, depending on whether or not change in mineralogy create significant variations in grindability. If such variation occurs, then the question is: how can it be simulated? This study could also provide a guideline for refining grinding models to account for such variations.
Improving Taconite Processing Plant Efficiency by Computer Simulation
(University of Minnesota Duluth, 2007-03-30) Bond, William M; Ersayin, Salih
This project involved industrial scale testing of a mineral processing simulator to improve the efficiency of a taconite processing plant, namely the Minorca mine. The Concentrator Modeling Center at the Coleraine Minerals Research Laboratory, University of Minnesota Duluth, enhanced the capabilities of available software, U sim Pac, by developing mathematical models needed for accurate simulation of taconite plants. This project provided funding for this technology to prove itself in the industrial environment. As the first step, data representing existing plant conditions were collected by sampling and sample analysis. Data were then balanced and provided a basis for assessing the efficiency of individual devices and the plant, and also for performing simulations aimed at improving plant efficiency. Performance evaluation served as a guide in developing alternative process strategies for more efficient production. A large number of computer simulations were then performed to quantify the benefits and effects of implementing these alternative schemes. Modification of makeup ball size was selected as the most feasible option for the target performance improvement. This was combined with replacement of existing hydrocyclones with more efficient ones. After plant implementation of these modifications, plant sampling surveys were carried out to validate findings of the simulation-based study. Plant data showed very good agreement with the simulated data, confirming results of simulation. After the implementation of modifications in the plant, several upstream bottlenecks became visible. Despite these bottlenecks limiting full capacity, concentrator energy improvement of 7% was obtained. Further improvements in energy efficiency are expected in the near future. The success of this project demonstrated the feasibility of a simulationbased approach. Currently, the Center provides simulation-based service to all the iron ore mining companies operating in northern Minnesota, and future proposals are pending with non-taconite mineral processing applications.
An Investigation of Seasonal Performance Variations in Taconite Plants
(University of Minnesota Duluth, 2009) Ersayin, Salih
The objective of this study was to analyze several sets of historical data representing winter and summer conditions using conventional and simulation tools to provide a better understanding of the cause, and to come up with ideas to alleviate the problem. The Coleraine Minerals Research Lab had historical plant data representing summer and winter conditions in a taconite plant. Two parallel lines (Lines 10 and 13) in the Minntac Plant were sampled during the winter and summer of 1995. Data included size structures of the streams in the magnetic separation circuit and head chemistries. However, limited information about the operating conditions was available. Particularly, certain essential data were missing, namely, prevailing hydrocyclone geometry and complete operating conditions during the summer sampling surveys. Nevertheless, it was anticipated that a simulation-aided analysis of this database could still reveal possible causes of performance deterioration during winter months, and could provide clues for performance enhancement to alleviate this negative effect.
Iron Ore Processing Improvements through Process Modeling and Computer Simulation
(University of Minnesota Duluth, 2001-06-15) Ersayin, Salih
In 1997, under the auspices of the Iron Ore Cooperative Research Program, iron ore mining companies operating on the Iron Range decided to work as a consortium in establishing expertise in the development of math models of individual taconite concentration operations and their use to simulate portions of the integrated concentration process. This led to the establishment in 1998 of the Concentrator Modeling Center within the Coleraine Minerals Research Laboratory (CMRL) of the University of Minnesota - Duluth. Following discussions on the type of software to be used by the Center, Usim Pac, mineral processing software developed by BRGM of France was selected due to the availability of a larger number of models, and model incorporation capability to add those to be developed in the future. The Center became fully operational when Dr. Salih Ersayin started to work as the program director on Nov. 1, 1999. While the application of modeling and simulation has provided significant benefits in the processing of base metal ores, its application to the processing of magnetic taconite has been hindered. This was caused by the need to incorporate the modeling of mineral liberation into the comminution models for size reduction steps, which occur between several stages of magnetic separation. An initial effort at integrating the modeling of size reduction, mineral liberation was carried out by Wiegel1 for the Erie Mining Company process in 1976. Plant scale implementation of the combined use process modeling and plant testing was reported for the National Steel Company secondary grinding section modifications 2 . Recently, Schneider 3 developed a mineral liberation model based on liberation characterization by scanning electron microscopy measurements. He validated his model using plant data obtained from the Fairlane Plant of Eveleth Taconite. For simulation purposes, he integrated his liberation approach into a ball mill grinding model. He also presented magnetic separator and hydrocyclone model structures compatible with the type of data produced by the liberation model. Despite of these developments, there still was a need to develop a simplified approach to the integrated size reduction/liberation model for taconite processing, models for magnetic separators, hydroseparators and fine screens, which would take into account the significant operating and design parameters. Therefore, the initial efforts of the Center were concentrated on development of simplified integrated mineral liberation/size reduction and magnetic separator models using funds allocated by the Permanent University Trust Fund (PUF), while providing a simulation service to taconite plant operators with the available software. Data from four plants in the Range taken as a part of an earlier Iron Ore Coop project was analyzed using the existing capabilities of the software. The data was first mass balanced and performance of individual pieces of equipment was examined. Results were presented to the plant engineers; their implications and potential improvements were discussed. To illustrate the capabilities of the software and potential benefits from the use of simulation, some modifications in plant flow sheets and operating/design conditions were simulated using the same data as a basis. These simulation results were also presented to the relevant engineers.
Iron Ore Processing Improvements through Process Modeling and Computer Simulation - 2003
(University of Minnesota Duluth, 2003-09-05) Ersayin, Salih
When the Concentrator Modeling Center was established in 1998, its first task was to define the prevailing conditions in terms of taconite plant simulation. Capabilities of existing software and unit operations needing improved models were defined. Preliminary simulations were carried out to determine how accurately the existing models could simulate taconite plant operations. Plant data was analyzed to determine how taconite plant operation could be simulated and to define the common problems and bottlenecks. It also provided some insight in terms of model development. This work indicated that there was a need for improved model development for the unit operations commonly used in taconite processing. Therefore, the Center's task was defined as "to develop advanced models, while providing simulation based assistance to the taconite plant operators using available simulation capabilities. n On the model development side, the specific objective was to develop improved models for magnetic separators, hydroseparators, fine screens and mineral liberation. Despite unsuccessful attempts to obtain federal funding for this type of work due to unwillingness of federal sources to fund projects that would benefit only a smaller section of the mining industry, the Center managed to improve the very simple models available for these unit operations using its plant database and limited funding for specific projects, Now it has the capability of simulating taconite processing more realistically. This was achieved . by analyzing available plant data and developing theoretical understanding of how these unit operations function, and along with pilot scale testing in the case of fine screen modeling. The Center's task was not only to develop these models, but also to incorporate them into the existing software, Usim Pac. Models for magnetic separators and hydroseparators were converted to the programming language of the software. The liberation model is expected to be incorporated soon. The Center's simulation efforts were concentrated on case studies involving the Evtac and lspat Inland plants. While replacing hydrocyclones in a ball mill grinding circuit with fine screens was the focus of study in the former plant, improving overall plant performance was the aim in the latter, which is still an on-going project funded by the DOE. Another simulation study was carried out to determine benefits of ore segregation in one of the taconite plants.
Liberation Characteristics of Taconite Plant Feeds
(University of Minnesota Duluth, 2007) Ersayin, Salih
A Purpose Oriented Magnetic Separator: Skimmer
(University of Minnesota Duluth, 2005) Ersayin, Salih
Taconite Concentrator Modeling the Next Phase
(University of Minnesota Duluth, 2007-08-29) Ersayin, Salih
The Concentrator Modeling Center, within the University of Minnesota Duluth, Natural Resources Research Institute's Coleraine Minerals Research Laboratory (CMRL) was established in 1998. Following an evaluation of current capabilities and limitations, the Center set its short-term objective as gaining the capability of carrying out reliable taconite plant simulations by using conventional modeling and simulation techniques. The long-term target was to achieve liberation-based simulations of taconite plants. The short-term objectives were achievable by improving the existing capabilities, whereas the long-term objective required development of an integrated size reduction/liberation model and its incorporation into the software, Usim Pac, used by the Center as a base. It was anticipated that completion and validation of such a model would take several years.
Taconite Concentrator Modeling ‐ 2005
(University of Minnesota Duluth, 2005) Ersayin, Salih

University Digital Conservancy

Browse by Author

Browsing by Author "Ersayin, Salih"