Design And Development Of High-Pressure Acid Leaching Training Simulation System

Operator training simulation systems have becoming increasingly important in process industry. The operator simulation training systems are particularly significant especially in the areas as follows:the new technology that is hard to find an actual infield training environment; the technology involve high temperature, high pressure and high acid in production process; the technology involves a complex operate process and has the highly skillful control of process parameters with high demands on the operator’s. Through the training of simulation system, operators can improve their qualities to reduce and avoid man-made factors that lead to accidents and property loss, while improving operators’abilities to handling abnormal working situations and emergency so that to improve production security and increase the device’s actual run cycle. Therefore, the design and development of simulation training systems have been paid more and more attentions.In this paper, we use the core part of a new smelting technology called high-pressure acid leaching technology for background. We design and development a high-pressure acid leaching simulation training system, the specific researches in this paper were summarized as follows:(1) The paper analyzed the high-pressure acid leaching process, its process control difficulties and the production factors.(2) The paper designed the process control software and the virtual object software component for the system’s software architecture and designed the operator station, the controller computer for the system’s hardware architecture. The function of operator station is to simulate DCS operating station, which is also running monitor program. The function of computer simulating controller is to simulate the controller, which is also running the control procedures. The function of the virtual plant computer is to simulate the production process of high pressure acid leaching, which is also running the process dynamic modeling of high pressure acid leaching.(3) The paper has made a detailed design study on control system software features according to the training needs of the simulation training software.Through simulating the real industrial field, the virtual software and the control software have made a completely simulation system of high-pressure acid leaching.They will achieve consistency with the industrial field control skills training, but also a more completely control to design, control algorithms and other skills test configurations.(4) Through the whole training simulation software testing, we can verify the simulation training software satisfys the training needs.The system implemented the whole industrial process simulation. The design includes startup, shutdown, normal operation, fault simulation and other aspects of training programs. The simulation system can simulate all conditions in production process, but also can receive a comprehensive training.