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Mimic Dynamic Simulation for Crushing Circuits
By Zach Sample
Product: Mimic Simulation

Mimic dynamic simulation application package for Crushing provides a high performance solution for operator training and control system optimization.

Mimic Explorer showing high fidelity models for the Crushing Circuit application package.

The virtual Crushing Circuit application package provides the complete environment for control system optimization and is an effective tool for teaching process and control engineers the control and operation of a crushing circuit.

Mimic Dynamic Simulation allows mine operation managers to:

  • Train operators on infrequent and dangerous process occurrences
  • Properly prepare an inexperienced operator workforce and create a smooth knowledge transfer process
  • Practice smooth operation of the process
  • Test control system enhancements
  • Increase overall plant safety and efficiency

This package uses the Mimic Mining Advanced Modeling Objects package for dynamic, real-time, first principles modeling. The Mimic Mining Advanced Modeling Objects are part of the Mimic Advanced Modeling Objects License that adds sophisticated modeling objects into the Mimic Simulation Studio modeling palette. These Objects can be used on Mimic systems for application software testing or operator training. The Mimic Advanced Modeling Objects License provides:

  • Medium to High Fidelity Simulation Performance
  • Rigorous First Principles process modeling supported by semi-empirical models using proven dynamic, real-time modeling methods
  • Modeling objects based on Unit Operations
  • Block to block communications of all parameters with one connection using Mimic Streams
  • Easy handling of individual stream component physical properties using Mimic Component Sets
  • Mimic OTM Process Snapshot support
  • Mimic OPC Server Access to all model parameters
  • Mimic OPC Bridge Communication with external Control Systems

In Mimic Simulation Studio, process models using these objects can be integrated with any other models or Mimic dynamic modeling blocks. All modeling objects in Mimic are IEC1131 function blocks. Models can be built off-line and then viewed executing on-line with real-time values from the Mimic Simulation engine. The process of going from off-line model building to on-line model tuning is fast and intuitive.

Crushing Circuit Dynamic Simulation

Mimic Dynamic Simulation of the Crushing Circuit provides accurate, real-time I/O updates to the off-line control system. The simulation consists of a collection of real-time, dynamic, first principles unit operation models configured to respond closely to the actual operations of the user’s facility. The MYNAH application package for the crushing circuit includes dynamic models of the following unit operations:

  • Feed Hopper
  • Belt Feeders
  • Conveyors
  • Jaw Crusher
  • Secondary Cone Crusher
  • Tertiary Cone Crushers
  • Vibrating Screens

The Crusher is rigorously modeled using Mimic’s Mining Advanced Modeling Objects. Included in this model are the following capabilities:

  • Dynamic, real-time material balance and particle size tracking of each component
  • Comminution determined via breakage matrices that vary with ore hardness, crusher level, and speed.
  • Power requirement modeled using Bond, Kick or Rittinger energy calculations
  • Jaw of cone type crushers
High Fidelity Dynamic simulation of a Crusher in Mimic Simulation Studio

As another component of Mimic’s Mining Advanced Modeling Objects, the screen is modeled to include the following capabilities:

  • Dynamic, real-time material balance and particle size tracking of each component
  • Realistic particle size classification, plugging and efficiencies
  • Multiple deck configurations

Instructor Station Environment

Instructor controls in Mimic and instructor screens in Mimic Component Studio allow your training team to prepare for working with the control system and process in the real plant. Any element in Mimic can be manipulated or controls, instructor screens provide easy access in one location. Typical instructor controls provided on instructor screens include:

  • Controls to manipulate operating conditions such as boundary conditions and compositions.
  • Utility quality and availability controls.
  • Snapshot restore controls to restore to desired operation sequence.
  • Training Scenario controls.
  • Ad-hoc device failure controls.
Crushing Circuit Instructor Station Graphic in Mimic Component Studio

Mimic Dynamic Simulation for Application Packages

Built for Operator Training and Control System Optimization. Because the dynamic simulation is built using Mimic Simulation Software, it fully supports operator training and configuration testing with any process control system environment. Mimic Simulated IO Drivers are non-intrusive and high performance, allowing IO simulation of any open process control system.

Easy to Customize and Modify. Mimic Operator Training Packages use Mimic Simulation Software Advanced Modeling Objects to deliver high-fidelity, dynamic process models. There is no hidden configuration in the solution. The user can easily modify the model to make it reflect the design of their plant design. The user can also add training scenarios and process snapshots as needed without limit.

Able to Work with Any Process Control System. Mimic models work directly with Mimic base level models and the Mimic Simulated IO System. This allows easy-to-maintain, accurate simulation of IO and control modules and provides real-time updates to the off-line control system.

Flexible, Powerful and Dynamic. The package is based upon Mimic Simulation Software; it is scalable from very small simulations to very large ones in the same software license. Mimic's multi-threaded simulation engine allows the fastest real-time performance of any simulation offering while still delivering accurate, dynamic simulations for a realistic operator experience at the control system operator station.

Scalable to Cloud Base Architecture. MYNAH Technologies is the industry leader in delivering cloud based dynamic simulation systems based upon VMware Virtualization Technology. MYNAH's Virtual Dynamic Simulators offer breakthrough flexibility and performance unavailable in legacy simulation architectures.

The virtual plant is an excellent platform for operators of crushing circuits to optimize their automation platform and address their operator training needs. Mimic Simulation Software is an enabling technology that addresses the needs of the energy industry process operators. See the Business Case for the Virtual Plant.

Ordering Information

For a quotation or more information on Mimic Dynamic Simulation for mineral processing plants, contact MYNAH Technologies at +1.636.728.2000 or