Aggflow Sample Training Agenda

Maximizing Plant Flow Production & Profitability ______________________________ AggFlow Training Session Charlotte, North Carolina February 18-19, 2009 ______________________________

Presented by Bob Bartok Vice President, Paschal Associates BS Metallurgical Engineering, Illinois Institute of Technology MBA, Indiana University

Hosted by Brian Lewis President & Inventor, BedRock Software

Helping Producers Maximize Profitability

Day 1 - Agenda 08:15

New User Orientation  AggFlow as a Benchmark  Basic Operations, Selecting Equipment, Connecting Flow Streams, Running the Plant  Sample Problems & Exercises

09:45

Break

10:00

Opening Remarks to Full Training Group  Establishing Goals & Objectives  AggFlow – The Plant Process Benchmark

10:05

Developing a Plant Layout  Getting Started, AggFlow Definitions, Setting User Preferences  Equipment, Flow Streams, Monitors, User Interface; AggFlow Tricks & Tips  Sample Problems & Exercises

12:00

Lunch

13:00

In Depth  Crushers; Database Assumptions; Interpolation of Gradations, Calculation Methods  Screens: Database Assumptions, Calculation Methods, Screen Area Efficiencies  Running The Plant; Red Flags, Maximizing Plant Flows, Applying Specifications  Reports, Graphs, Using Color & Making Notes on Worksheets  Sample Problems & Exercises

14:45

Break

15:00

Advanced Features  Apply specifications, Modes, Blending, Dust Calculations and Conveyors  Creating Multi-page Plants, Importing & Exporting to Excel, Internet Features  Sample Problems & Exercises

16:30

Day 1 Wrap-Up and Q&A

17:30

AggFlow Management Team Reception

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Helping Producers Maximize Profitability

Day 2 - Agenda 08:15

Day 1 Review  Developing a Plant Layout, Crushers, Screens, Reports & Graphs, Advanced Features

08:30

Wash Equipment  Sand Screws, Classifying Tanks, Cyclones & Separators, Black Box  Sample Problems & Exercises

09:30

Water Mass Balance Calculations  Using Water in a Plant, Pumps, Water Pipes, Slurry Pipes, Adding Water Sources,  Spray Bars, Use of Water in Product, Clarifiers & Thickeners, Water Loss  Sample Problems & Exercises

10:45

Break

11:00

Measurements  Sample Buckets, Belt Scales, Measuring Flow Rates & Gradations  Measuring Crushers, Screens, Stock Piles and Validating Calculations in Plant Data  Sample Problems & Exercises

12:30

Lunch

13:30

Fine-Tuning Your Calculations & Plant Designs  Calculation Levels 1, 2 & 3  Bottlenecks AggFlow Cannot Account For

14:30

Final Steps to Improve & Increase Production  Establishing Benchmarks  Comparing Measured Values to Calculated values  Screens, Crushers, HSI’s, Cones  Sample Problems & Exercises

15:30

Day 2 Wrap-Up and Q&A

14:30

Departure

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Helping Producers Maximize Profitability

 New User Orientation  AggFlow As A Benchmark

Users Around the Globe Employ AggFlow for:  Total Plant Flow Simulation & Analysis

 Gradation Definition

 Aggregate Mass Balance Calculations

 AggFlow Equipment Categories

 Water Mass Balance Calculations

 Placing Equipment On The Worksheet

 Independent Equipment Selection

 Selecting & Adjusting Specific Equipment

 Conduct “What-If?” Scenarios

 Connecting The Equipment With Flow Streams

 Experiment with Different Equipment & Settings

 Apply Monitors To See Results

 Switch to Different Operating Modes Instantly

 “Run” The Plant

 Justify New Investment by Comparing Set-ups

 Your Best Resource: Select Help, then Open Manual

 Fine-Tune Equipment Operation

 Simple Plant Setup

 Identify Plant Inefficiencies & Bottlenecks

Example #1: Setup and Experiment a Simple Plant  Reduce Calculation Time  Improve Fuel Consumption & Emissions  Customize Plant Calculations and Reports

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Helping Producers Maximize Profitability

 Introduction To AggFlow  BedRock Mission: Help Producers Maximize Profitability 

Review processes in existing plants; Find plant process & production bottlenecks

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More TPH from same equipment

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Assist in correct equipment choices

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Accurately target plant production and product mix to meet sales forecast

 AggFlow History 

Story of the thumb that controlled profitability

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Continuous development since 1993

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Currently employed in 63 countries

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Installed on your computer is the latest version of AggFlow (200811) Includes Water Mass Balance Calculations & French/Spanish Translation

 In This Training Class 

We encourage interaction and discussion with your neighbor

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We welcome feedback, suggestions & observations during the class

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Please do each sample as it will be expanded upon throughout the class

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Feel free to repeat and experiment with different options in the samples

 OUR GOAL: Tomorrow Afternoon You Will Be Highly Proficient Using AggFlow 

Make AggFlow your plant process benchmark

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Layout any type of plant

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Identify and resolve bottlenecks

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Make AggFlow accurate for your plant

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Know what questions to ask to improve overall efficiency

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Produce plant files, equipment and production reports & graphs

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Optimize Plant Production and Maximize Profitability

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Helping Producers Maximize Profitability

 Developing A Plant Layout  What AggFlow Is & What AggFlow Is Not: How To Use This Tool 

Benchmark

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Extremely Sophisticated Calculation Tool (Aggregate  :  Water)



AggFlow is not artificial intelligence – It does not think for itself

 What You Need to Start Using AggFlow: 

Initial feed gradation This is hard to measure given the sizes are typically larger than 8 inches. The most important factor in the feed gradation is the value passing the first screening point. For example, if the feed is going to a grizzly feeder with a 5 inch bar opening, then you want an accurate value for the 5 inch percent passing value. Example #2: See: Feed Source Secondary Surge Pile Gradation.pdf

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Major equipment in the plant Note: AggFlow plant flow calculations can be performed with or without modeling the conveyors.

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Crusher makes, models and settings

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Screen sizes and mesh openings

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Overall flow of material through the equipment in the plant

 AggFlow Menu Definitions File Edit

View Run

Database Selected Object

Summary Modes

Windows

Help

 Setting User Preferences User Units Washing Screen Area Display Titles Lines-Grid Display Size Ranges Saving The Plant

HTTP Setup

Tolerance

Update

 Create a Plant From The Hand Drawn Flow Sheet Example #3: See: Rough Sketch.pdf

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Helping Producers Maximize Profitability

 Developing A Plant Layout (continued)  Equipment Placement & Layout 

Effect of initial feed on plant accuracy

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Equipment descriptions - top level

 Flow Stream Layouts 

Initial connections

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Adjusting bend points

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Orthogonal lines

 Add Monitors To See Results

 “Run” The Plant

 User Interface 

Zoom features

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Multiple selections using shift key

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Copy/paste blocks

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Graphical Undo

 Plant Configuration Advisor – How to use it

 AggFlow Tricks 

Multiple windows can be open at once

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Read the bottom panel for information!

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Always keep your program updated

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Use your best resource – Open the manual!

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Helping Producers Maximize Profitability

 Crushers  Crusher Database Assumptions

 Model Selection 

Manufacturer limits



Book gradations

 Interpolation of Gradations

 Reduction Ratio Monitoring

 Calculation Method 

You are in complete control of the output gradations. AggFlow does not calculate automatically.  AggFlow does not calculate an output gradation based on changes to input gradations  You must specify the output gradation by adjusting the equipment set-up in the program

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AggFlow actually ignores the input gradation and relies completely on your output specifications

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AggFlow does pay attention to the incoming flow rate and ensures mass balance

 Some Impact Crushers Track Input Size Range

 Sample of Making Larger Rocks Out of Smaller Rocks 

Put sand and gravel into a jaw Example #4: Sand to Jaw Example #5: Bad HSI

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Helping Producers Maximize Profitability

 Crushers (continued)  Common Mistakes 

Modeling mistakes  Not sized correctly  Not set correctly

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Operational mistakes  Not maintained  Not fed correctly (Crushers & Screens)  Not loaded near capacity  Book crusher data not correct for equipment application

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Helping Producers Maximize Profitability

 Screens  Vibrating Screen Database Assumptions

 Model Selection 

Adjust as needed

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Add new size to database

 Calculation Methods 

VSMA

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Open VSMA sheets

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Cedarapids

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Deister

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Scalper calculation

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DBD discussion & efficiency

 Screen Area Efficiency 

Screen carry over

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Set specific size

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Adjust sizes and screen efficiency

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Refer to results to investigate effects of size and efficiency changes

 Using Screen Efficiency To Model Different Mesh Openings 

Using the screen efficiency override method

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Helping Producers Maximize Profitability

 Screens (continued)  Missing from VSMA 

Non-wire deck area requirements

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Open area adjustment

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Varies from one manufacturer to the next

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Multi-openings same deck

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Non standard screens

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Pep screens

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Banana screens

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Refer final design to manufacturer

 Common Mistakes 

Modeling mistakes

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Not sized correctly

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Equipment not set-up correctly

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Other constraints; conveyors, chutes and feeders

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Misapplication of equipment

 Operational Mistakes 

Equipment is not maintained

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Screen is not fed correctly

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Screen operating parameters

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Wrong media

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Wrong flow direction

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Water amounts

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No correction for screen operational parameters

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Under loaded screens Example #6: Under Loaded Screen

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Helping Producers Maximize Profitability

 Running The Plant  Red Flags Note: AggFlow highlights problem areas and equipment exceeding warning levels by turning the equipment in the worksheet red. However, the program will continue to perform calculations as if there was no problem. Therefore, you can choose to address, or ignore, red flags at anytime.

 Warning Levels 

Three warning levels:  Alarms; AggFlow alerts you when calculated results may not match field results  Warnings; Items to be aware of, will not likely affect calculations or results  Missing Limits; Manufacturers have not supplied crusher limits and AggFlow has no limits here Example #7: Warning Levels

 Maximize Plant Production Feature 

Runs the plant to maximize crusher capacities



Does not take into account screens & conveyors

 Apply Specifications

 Product Mix

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Helping Producers Maximize Profitability

 Reports, Graphs, Using Color & Making Notes on Worksheets  Saving Settings 

Save multiple files (unlimited)

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AggFlow View Results defaults to last view saved

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Automatic Save (set time period in User Preferences)

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File Recapture – in a system crash, AggFlow will provide the option to recapture/save unsaved files

 AggFlow File Protection 

Turns the Specific AggFlow worksheet into read only (find it under FILE, then Protection)

 3-Deck Screen Example 

View results & reports for a 3-deck screen.

 PDF Reports 

Worksheet and results

 Title Block Info 

Company and name stay with sheet

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Run version – identifies the last time the plant was run in the printout

 Spreadsheet Reports 

Provides complete report and equipment list in spreadsheet format

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You can select individual or a selection of line items (hold the SHIFT key)

 Coloring and Making Notes on the Worksheet 

Highlight, color and make notes on the worksheet

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Helping Producers Maximize Profitability

 Advanced Features  Apply Specifications 

Specification database Example #8: Goal - Figure out how to get sample to meet spec

 Modes 

Modes allow unlimited number of plant setups within each plant file Example #9: Goal 1 – Use Modes to optimize the same plant for two different products Example #10: Goal 2 – Use Modes to add a splitter and a new crusher to an existing plant

 Blending 

Simple Blend Demo

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Linear programming info Example #11: Goal – Determine how many products this plant can make

 Dust Calculations Example #12: Simple Dust Example

 Conveyors 

Calculation methods Example #13: Simple Conveyor Example

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Helping Producers Maximize Profitability

 Advanced Features (continued)  Creating Multi-Page Plants 

Linking Pages

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Review of Equipment That Can be Linked

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Looping Back to First Page

 How Big Can Plants Get? 

See: bigPlant.pdf Example #14: Split plant into three pages

 Monitor “Layers” Example #15: Monitors - Create a TPH and a Settings Monitor Layer

 Import/Export to Excel Example #16: Export AggFlow data to Excel, change it, Import the data back to AggFlow

 Internet Features 

Get Automatic Updates (regularly!)

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Send emails & plant files from within program

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Automatic error reporting

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Send plant files directly to AggFlow Team for review/help

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Send support requests and suggestions to AggFlow Team from within program

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Create PDF, JPEG and TIFF files

 DAY 1 Wrap-Up – Q&A

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Helping Producers Maximize Profitability

 Day 1 Review  Developing a Plant Layout  Initial feed gradation; Major equipment in the plant; Crusher makes, models & settings; Overall flow of material; Equipment & flow stream layouts; Monitors; Running the plant; Customizing AggFlow with user preferences; Reports & printouts.

 Crusher Selection 

Database assumptions; Model selection; Reduction ratios; Calculation methods; Common modeling and operational mistakes.

 Screens 

Database assumptions; Model Selection; Calculation methods; Screen area calculations & efficiencies; Calculation methods; Common modeling and operational mistakes.

 Running The Plant 

Red flags; Warning levels; Running with Screen area adjustments; Product mix.

 Reports & Graphs 

Saving settings; PDF reports; Titles & printout labels; Spreadsheet Reports.

 Advanced Features 

Applying specifications; Modes; Blending: Dust calculations; Conveyors; Multi-page Plants; Monitor Layers; Importing/exporting to Excel; Internet Features.

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Helping Producers Maximize Profitability

 Wash Equipment  Sand Screw 

Basic operation and AggFlow simulation

 Classifying Tank

 Cyclones & Separators

 Black Box – Dewatering Screen  Example of Creating a Wash Plant Example #17: Create a Wash Plant from Sketch

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Helping Producers Maximize Profitability

 Water Mass Balance Calculations  Using Water in an Accurate Plant 

Input water into feed

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Converting flow streams to slurry pipes

 Adding Water Sources 

Screen spray bars



Use of water in product

 Fresh Water Piping 

Pumps

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Clarifiers & Thickeners

 Water Loss in an Accurate Plant  Example of Creating a Plant with Water Mass Balance Calculations Example #18: Add Water Mass Balance Features to Wash Plant

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Helping Producers Maximize Profitability

 Measurements  Sample Buckets 

Quality Control Samples plugged in the flow calculations Example #19: Install Sample Buckets Example #20: Demo Excel Interface

 Belt Scales Example #21: Install Belt Scales

 Measure Flow Rates and Gradations 

Feed material gradation



Variability in feed gradation and making it accurate

 Flow Rate 

Typical Flow  Primary in-feed not measured

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Optimum Flow  Detailed gradation below 4 to 7 inches  % of oversize material

 Crushers 

Typical  None

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Optimum  Input gradation  Output gradation

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Helping Producers Maximize Profitability

 Measurements (continued)  Screens 

Typical  None

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Optimum  Output gradations

 Stock Piles 

Typical  Gradations

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Optimum  Gradations and rates

 Methods to Validate Calculations with Plant Data 

Statistical history

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Field measurements

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Observations Example #22: Real Life Examples of Measurements

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Helping Producers Maximize Profitability

 Fine-Tuning Your Calculations & Plant Designs  Why Do So Many Operations Continue Along With Known Bottlenecks?

 Calculation Levels 

Level 1  Setup with generic data  If you have average material with standard compression crushers this gets you to level 2  If you have impact crushers you may or may not get to level 2  Data varies greatly from one manufacturer to the next  You may need crusher samples to get past this point  Results may be off - but experts report that incremental change is usually very good

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Level 2  Take plant measurements to verify results  May identify problems  Experienced aggregate manager uses this model to identify improvements and problems

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Level 3  You have enough data to totally optimize production with accurate results  You reach a point where "what if" calculations are consistently accurate and reliable. Use your experience to estimate where that point is.

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Helping Producers Maximize Profitability

 Fine-Tuning Your Calculations & Plant Designs (Continued)  Bottlenecks AggFlow Cannot Account For Or Calculate

 Material From the Pit  Transport Equipment  Feeders  Stock Pile Capacity  Surge Pile Capacity  Segregated Material Flow  Transfer Chutes

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Helping Producers Maximize Profitability

 Final Steps To Improve & Increase Production  Establish Benchmark Example #23: Sample Plant File Example #24: Determine Bottlenecks

 Compare Measured Values to Calculated Values 

Actual settings do not match current design

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Make sure crushers as doing as expected

 Screens 

Monitor efficiency

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Size adequate?

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Change mesh openings

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Lower rate

 Crushers 

Try to maintain design capacity Example #25: Sample File Reviews Example #26: Evaluate Sample for Accuracy

 HSI With Standard Data

 Cone With Standard Data

 DAY 2 Wrap-Up – Q&A

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