VEST Operations, LLC

Process Control
Training
5.9.2018
UNDERSTANDING OUR PROCESS

• WHAT IS OUR GOAL?

• DO WE KNOW THE PROCESS?
• INPUTS VS. OUTPUTS
• HOW DO WE USE DATA TO HELP US?
THE GOAL OF THE PROCESS - DRY

• MEETS CUSTOMER EXPECTATIONS

• MAXIMIZE YIELD
• MAXIMIZE 4070 PRODUCTION
• MINIMIZE WASTE
• HOW DO WE USE DATA TO HELP US?
THE PROCESS

DRYER SCREENS SILOS

MORE DETAILED PROCESS….

• FEED INPUT GRADATION

• DRYER TPH OUTPUT
• ROTEX FEEDER TPH
• # ROTEXS OPERATIONAL
• ROTEX SCREEN SET UP AND CONDITION
• CHUTE ARRANGEMENT
ROTEX SYSTEM
ROTEX
ROTEX
ROTEX
ROTEX CHUTES
ROTEX CHUTES

OVERS
SCREEN
MEDIA

PRODUCT
SCREEN
MEDIA

FINES
PAN

P O O P
F F
PLANT
CHUTE
S
MANY POSSIBILITIES….INPUTS
MANAGING THE INPUTS

• DRYER TPH
• INDIVIDUAL FEEDER TPH
• SCREEN MEDIA SET UP
• SCREEN MEDIA CONDITION
• CHUTE SET UP

TO CONTROL THE OUTPUT….

4070 IN DETAIL…
4070 IN DETAIL…
100 MESH IN DETAIL…
100 MESH IN DETAIL…

42.3% plus
70
 1045 0 0.2 3.8 12.4 29.4 28.4 16.1 6.2 2.1 1.2 0.2 0.603 0.711 86 400

ANALYSIS
1145 0 0.2 3.7 11.8 27.7 29.1 16.7 6.2 2.2 1.7 0.7 0.599 0.711 115 118
1245 0 0 0.8 8.5 31.3 24.2 22.7 8.3 2.8 1.2 0.2 0.601 0.709 102 117
1345 0 0.2 2.7 11.9 31.2 27.2 17.4 6.1 2 1.1 0.2 0.603 0.712 113 242
1545 0.1 0 3.8 13.6 30.2 26.7 17 5.9 1.7 0.9 0.1 0.604 0.709 158 349
1645 0 0.1 2.7 9.9 28.7 28.3 19 7.1 2.4 1.5 0.3 0.599 0.711 135 391
1745 0 0.1 2.4 8.9 25.7 27.7 20.5 8.8 3.2 2.2 0.5 0.598 0.711 146 440
1845 0 0.2 2.8 10.6 28.3 28.1 19.2 7.1 2.3 1.2 0.2 0.607 0.711 148 359
1945 0 0.1 3.2 10.2 25.9 29.3 18.7 7.5 2.8 1.9 0.4 0.598 0.711 144 317
2045 0 0.1 2.2 8.6 27.4 29.2 20.8 7.8 2.5 1.2 0.2 0.601 0.71 155 350
2145 0 0.1 2.6 8.7 24.2 29.3 19 8.6 3.6 3.1 0.8 0.596 0.711 135 406
2245 0 0.1 1.8 7.6 23.1 29.5 21.3 9.4 3.6 2.8 0.8 0.597 0.71 168 388
2345 0 0.1 2.1 8.3 27.8 27.3 22 8.3 2.7 1.3 0.1 0.597 0.71 128 301
0045 0 0.2 3.8 11.3 26.6 32 16.3 6.5 2 1.2 0.1 0.599 0.712 115 387
0145 0 0.2 2.2 8.9 26.5 30.6 19.4 7.7 2.6 1.6 0.3 0.604 0.711 166 325
0245 0 0.1 2.7 9.9 27.4 29.7 19.3 7.2 2.3 1.3 0.1 0.601 0.713 171 395
0345 0 0.1 2.8 9 24.1 30.6 19.2 8.3 3.1 2.2 0.6 0.593 0.711 172 317
0445 0 0.2 2.6 9.4 26.9 27.3 20.9 8.2 2.7 1.6 0.2 0.603 0.712 158 340
0545 0 0 2.5 8.8 25.9 30.3 20.1 8.1 2.7 1.4 0.2 0.598 0.71 178 386
Mean: 0.0 0.1 3.0 10.3 27.4 28.2 18.5 7.5 2.8 1.9 0.3 0.6 0.7 137.6 321.6
Std Dev 0.05 0.06 1.06 1.93 2.3 1.75 1.88 1.04 0.64 0.77 0.21 0.0037 0.0013
30 40 50 60 70 80 100 120 140 200 PAN Round Sphere Turbidity TPH
MAX 0.7 0.4 6.9 18 33.5 33 22.8 10.1 4.8 5 1 0.607 0.716 279 473
MIN 0 0 0.8 5.2 21.3 23.5 11.6 4.5 1.2 0.4 0 0.574 0.707 68 108

- 3 STD DEV -0.1 -0.1 -0.1 4.5 20.5 22.9 12.8 4.4 0.9 -0.4 -0.3
- 2 STD DEV -0.1 0.0 0.9 6.4 22.8 24.7 14.7 5.5 1.6 0.4 -0.1
- 1 STD DEV 0.0 0.1 2.0 8.3 25.1 26.4 16.6 6.5 2.2 1.1 0.1
MEAN 0.0 0.1 3.0 10.3 27.4 28.2 18.5 7.5 2.8 1.9 0.3
+1 STD DEV 0.0 0.2 4.1 12.2 29.7 29.9 20.3 8.6 3.5 2.7 0.5
+2 STD DEV 0.1 0.2 5.1 14.1 32.0 31.7 22.2 9.6 4.1 3.4 0.8
+3 STD DEV 0.1 0.3 6.2 16.1 34.3 33.4 24.1 10.7 4.8 4.2 1.0
 0045 0 0.2 3.8 11.3 26.6 32 16.3 6.5 2 1.2 0.1 0.599 0.712 115 387
0145 0 0.2 2.2 8.9 26.5 30.6 19.4 7.7 2.6 1.6 0.3 0.604 0.711 166 325
ANALYSIS 0245 0 0.1 2.7 9.9 27.4 29.7 19.3 7.2 2.3 1.3 0.1 0.601 0.713 171 395
0345 0 0.1 2.8 9 24.1 30.6 19.2 8.3 3.1 2.2 0.6 0.593 0.711 172 317
0445 0 0.2 2.6 9.4 26.9 27.3 20.9 8.2 2.7 1.6 0.2 0.603 0.712 158 340
0545 0 0 2.5 8.8 25.9 30.3 20.1 8.1 2.7 1.4 0.2 0.598 0.71 178 386
Mean: 0.0 0.1 3.0 10.3 27.4 28.2 18.5 7.5 2.8 1.9 0.3 0.6 0.7 137.6 321.6
Std Dev 0.05 0.06 1.06 1.93 2.3 1.75 1.88 1.04 0.64 0.77 0.21 0.0037 0.0013
30 40 50 60 70 80 100 120 140 200 PAN Round Sphere Turbidity TPH
MAX 0.7 0.4 6.9 18 33.5 33 22.8 10.1 4.8 5 1 0.607 0.716 279 473
MIN 0 0 0.8 5.2 21.3 23.5 11.6 4.5 1.2 0.4 0 0.574 0.707 68 108

- 3 STD DEV -0.1 -0.1 -0.1 4.5 20.5 22.9 12.8 4.4 0.9 -0.4 -0.3
- 2 STD DEV -0.1 0.0 0.9 6.4 22.8 24.7 14.7 5.5 1.6 0.4 -0.1
- 1 STD DEV 0.0 0.1 2.0 8.3 25.1 26.4 16.6 6.5 2.2 1.1 0.1
MEAN 0.0 0.1 3.0 10.3 27.4 28.2 18.5 7.5 2.8 1.9 0.3
+1 STD DEV 0.0 0.2 4.1 12.2 29.7 29.9 20.3 8.6 3.5 2.7 0.5
+2 STD DEV 0.1 0.2 5.1 14.1 32.0 31.7 22.2 9.6 4.1 3.4 0.8
+3 STD DEV 0.1 0.3 6.2 16.1 34.3 33.4 24.1 10.7 4.8 4.2 1.0
 NORMAL DISTRIBUTION

-4σ -3σ -2σ -1σ Mean +1σ +2σ +3σ +4σ

 NORMAL DISTRIBUTION

-4σ -3σ -2σ -1σ Mean +1σ +2σ +3σ +4σ

 NORMAL DISTRIBUTION

-4σ -3σ -2σ -1σ Mean +1σ +2σ +3σ +4σ

 NORMAL DISTRIBUTION

99.7%

-4σ -3σ -2σ -1σ Mean +1σ +2σ +3σ +4σ

 0045 0 0.2 3.8 11.3 26.6 32 16.3 6.5 2 1.2 0.1 0.599 0.712 115 387
0145 0 0.2 2.2 8.9 26.5 30.6 19.4 7.7 2.6 1.6 0.3 0.604 0.711 166 325
ANALYSIS 0245 0 0.1 2.7 9.9 27.4 29.7 19.3 7.2 2.3 1.3 0.1 0.601 0.713 171 395
0345 0 0.1 2.8 9 24.1 30.6 19.2 8.3 3.1 2.2 0.6 0.593 0.711 172 317
0445 0 0.2 2.6 9.4 26.9 27.3 20.9 8.2 2.7 1.6 0.2 0.603 0.712 158 340
0545 0 0 2.5 8.8 25.9 30.3 20.1 8.1 2.7 1.4 0.2 0.598 0.71 178 386
Mean: 0.0 0.1 3.0 10.3 27.4 28.2 18.5 7.5 2.8 1.9 0.3 0.6 0.7 137.6 321.6
Std Dev 0.05 0.06 1.06 1.93 2.3 1.75 1.88 1.04 0.64 0.77 0.21 0.0037 0.0013
30 40 50 60 70 80 100 120 140 200 PAN Round Sphere Turbidity TPH
MAX 0.7 0.4 6.9 18 33.5 33 22.8 10.1 4.8 5 1 0.607 0.716 279 473
MIN 0 0 0.8 5.2 21.3 23.5 11.6 4.5 1.2 0.4 0 0.574 0.707 68 108

- 3 STD DEV -0.1 -0.1 -0.1 4.5 20.5 22.9 12.8 4.4 0.9 -0.4 -0.3
- 2 STD DEV -0.1 0.0 0.9 6.4 22.8 24.7 14.7 5.5 1.6 0.4 -0.1
- 1 STD DEV 0.0 0.1 2.0 8.3 25.1 26.4 16.6 6.5 2.2 1.1 0.1
MEAN 0.0 0.1 3.0 10.3 27.4 28.2 18.5 7.5 2.8 1.9 0.3
+1 STD DEV 0.0 0.2 4.1 12.2 29.7 29.9 20.3 8.6 3.5 2.7 0.5
+2 STD DEV 0.1 0.2 5.1 14.1 32.0 31.7 22.2 9.6 4.1 3.4 0.8
+3 STD DEV 0.1 0.3 6.2 16.1 34.3 33.4 24.1 10.7 4.8 4.2 1.0
 RETAINED ON 70 SIEVE IN 100 MESH

99.7%

-4σ 20.5 22.8 25.1 27.4 29.7 32.0 34.3 +4σ

 RETAINED ON 60 SIEVE IN 100 MESH

99.7%

-4σ 4.5 6.4 8.3 10.3 12.2 14.1 16.1 +4σ

OUR DATA….4/15 THRU 5/5 4070
0945 0 2.3 16.1 28.1 32.3 15.1 4.4 1.4 0.3 0.614 0.72 93 155 91.6
1045 0.1 1.9 12.2 26.8 35.2 17.2 5 1.3 0.3 0.609 0.713 187 75 91.4
1145 0 2.2 15 28.4 33.2 15.6 4.3 1.1 0.2 0.616 0.719 79 61 92.2
1245 0 1 12 30.8 40.4 13 2.1 0.6 0.1 0.619 0.72 77 98 96.2
1345 0 1.7 13.8 29.1 36.2 14.8 3.5 0.8 0.1 0.616 0.716 94 105 93.9
1545 0.1 3 19.2 33.1 31 10.8 2.3 0.4 0.1 0.611 0.72 113 253 94.1
1645 0 2 13.4 28.8 35.1 15.2 4.4 0.9 0.2 0.613 0.718 98 166 92.5
1745 0 1.8 14.1 27 35.3 15.8 4.8 1 0.2 0.614 0.717 104 170 92.2
1845 0 1.5 13.3 26.8 35.7 16.6 4.8 1.1 0.2 0.615 0.718 119 153 92.4
1945 0 1.5 12.1 25.1 36.9 18.2 5 1 0.2 0.616 0.716 112 138 92.3
2045 0 1.3 12.6 26.5 35.7 17.1 5.3 1.3 0.2 0.616 0.715 128 145 91.9
2145 0 1.4 12.5 27.6 37.2 16.4 4.1 0.7 0.1 0.615 0.718 90 174 93.7
2245 0 2.1 14.2 27.1 34.4 15.8 4.8 1.3 0.3 0.613 0.716 119 158 91.5
2345 0 1.3 12 26.5 36.2 17.6 5.2 1 0.2 0.617 0.716 97 135 92.3
0045 0 1.6 9.6 23.8 37 19.7 6.3 1.7 0.3 0.616 0.715 89 161 90.1
0145 0 1.6 12.7 26.8 37.2 16.6 4.1 0.8 0.2 0.615 0.717 112 136 93.3
0245 0 1.4 12.8 25.6 34.8 17.3 5.8 1.8 0.5 0.617 0.718 108 171 90.5
0345 0.1 2.7 16.5 28.9 33.9 13.8 3.3 0.7 0.1 0.615 0.719 124 131 93.1
0445 0 1 10.9 26.6 36.6 17.8 5.4 1.4 0.3 0.614 0.719 125 139 91.9
0545 0.1 1.2 13.8 28.8 36.3 15.3 3.6 0.8 0.1 0.614 0.717 125 159 94.2
Mean: 0.0 1.6 12.5 25.7 34.7 17.7 5.7 1.6 0.4 0.6 0.7 99.7 161.9 90.6
Std Dev: 0.05 0.49 1.98 2.14 1.42 2.2 1.16 0.53 0.22 1.641
 99.70%
95%
68%
GSD 85.72 87.36 89.01 90.65 92.29 93.93 95.57
-3σ -2σ -1σ Mean +1σ +2σ +3σ
2.30% 16% 34% 34% 16% 2.30%

Plus 40 Mesh 0.1247 0.6165 1.1082 1.6 2.0918 2.5835 3.0753

VARIABLES TO MANAGE

• FEED MATERIAL GRADATION

• ROTEX SCREEN SET UP
• FEEDER TPH
• GATE SET UP
SCREEN SET UP 4
PHILOSOPHY 2

7
4

PLAN AS OF 5/8/18…
6
6 OVER
S
7 C305
4 4070
C308

100M 100M
C309 C309 C309 C308
4
TEST, TEST, TEST UNTIL YOU KNOW
2

7
4

6
6 OVER
S
7 C305
4 4070
C308

100M 100M
C309 C309 C309 C308
STANDARDS

• REACT TO TWO SAMPLES BELOW 91

• GRADATION ASAP, RETEST FAIL ASAP
• 2ND TEST FAILS, PLANT MUST REACT
• COMMUNICATE MODIFICATIONS
• PROBLEM SOLVED WITHIN 2 HOURS
QUESTIONS ??