Grinding and flotation optimization in minerals processing with ABB Ability™ Expert Optimizer

ABB Ability™ Expert Optimizer, ABB’s Advanced Process Control (APC) solution using straightforward design and deployment of model predictive control (MPC) with ABB Ability™ System 800xA DCS enables higher level of automation and optimization in a grinding and flotation circuit example.

Want to optimize grinding and flotation using real time data and detect changes to ore grade as it is extracted?

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In a typical grinding circuit ore is fed into the mills where abrasion, attrition and impact reduce its size. Usually, the grinding circuit contains at least two interconnected mills with material classifiers (e.g. cyclones) separating the fine material from the coarse (that then goes for regrinding).

The process is energy intensive with power consumption of roughly 20 to 30 MW and feed throughputs of 2,500 to 3,000 t/hr. Process variables are mill loads, motor torque and power, plus pressures and flow rates. The ground product is specified in terms of fineness.

The typical results of an APC controller are increased throughput, homogeneous product quality, reduced consumables and lower maintenance costs.
Further, ABB Ability™ Expert Optimizer can be advantageously deployed in the flotation plant, where the ground ore, now in slurry form, is “washed” to separate valuable minerals from waste. The goal is maximum production or maximum yield at a given concentrate quality. 

ABB Ability™ Expert Optimizer performs timely adjustments to froth levels, air flows and reagents leading to process stabilization, minimized reagents and increased recovery.

References

Improved grinding at Boliden Aitik mine in Sweden
  • Improved throughput – Ranged from 1% to 3%
  • Improved maximization of torque – Ranged from 1% to 7%
  • Improved disturbance rejection – Ranged from 0.5% to 3.5%
  • Improved response time and circuit stability – Reduced STD > 5%
Increased flotation efficiency at Boliden Garpenberg mine in Sweden
  • Recovery increased by 1%
  • Reduction of variability in product grade
  • Increased stability of froth levels and reagent consumption

*Results gathered over a two month evaluation

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ABB Ability™ Performance Optimization for mining

Assess your improvement potential based on current plant operation, stabilize and optimize performance with advanced process control, automate maintenance and performance reporting

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Model predictive control technology
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