ABB Ability™ Expert Optimizer for mining

Advanced Process Control (APC) applications designed by process experts, customized to your needs to stabilize production while maximizing profitability

Delivering high-quality products while keeping production costs low and plant efficiency high — after more than 20 years serving the mineral processing industry we know your challenges. And we have cutting-edge solutions available to support you in overcoming them.

We have bundled our long-lasting expertise in grinding circuits, ore benefication, flotation and other proceses, into our advanced technologies for process optimization - ABB Ability™ Expert Optimizer (EO). Based on proven ABB know-how and with a user-friendly interface our solutions enable your operator to optimize your entire process — at the push of a button.

Advanced Process Control

How mining and minerals processing industry can benefit from model predictive control technology to reduce costs and increase yields

Your challenge

Our solution

Features

Benefits

Consistently deliver specified quality products while keeping production costs low and plant efficiency high
Manage difficulties of variable ore and raw materials
Minimize energy and water usage
Minimize shift-to-shift variations of your plant operation

Modern advanced process control techniques, including linear and non-linear Model Predictive Control, Fuzzy Logic etc.
Easy to use controller design tools
Ready-made control applications designed by process experts covering the entire mining process

Grinding circuit optimization
Material grinding (and crushing) is one of the most important steps in extracting minerals from ores. Optimal design of grinding circuits for both consistent product quality and energy efficiency is crucial for the minerals plant’s performance. Control of grinding circuits is difficult due to significant time delays and time lags in the process and due to variable material properties of the incoming ore. ABB's solution for comminution optimization offers:

Optimal output at given product quality
Better performance of downstream processes due to better control of the grinding process
Increased mill liner lifetime

Flotation optimization
Flotation is a key process in many mineral plants to separate the product mineral from the gangue. The key requirement of the system is to achieve optimum product quality with minimum reagent consumption. Control is difficult due to variable chemistry and size distribution of the material fed to the process. ABB's solution for flotation optimization offers:

Improved circuit control to optimize separation of the product from gangue
Optimum reagent consumption

Kiln and calciners optimization
Kilns and calciners are used in many minerals processing plants either as an intermediate process or as a final step to produce a finished product. The process is characterized by high fuel consumption. Control is difficult due to internal cycles in the kiln and the uncertain raw material properties.
ABB's solutions for kilns offer:

Consistent control of the temperature profile
Optimization of the temperature profile to minimize fuel consumption
Reduced product variability
Longer campaigns by increasing the life of the refractory lining
Increased output by reduction of process disturbances

Tangible benefits
Typically process optimization will enhance your kiln, your communition, and your batch-continuous process scheduling as well as control your flotation. Expected benefits of a process optimization deployment project are:

Increased recovery by 1 to 2%
Reduced quality variability by 25%
Energy savings 3 to 5%
Increased liner lifetime 10%
Reduced grinding media consumption 5 to 10%
Lower emission levels 3 to 5%

Qualitative benefits

Operational discipline
Environmental compliance

Learn more

Model predictive control technology demystified

ABB Ability™ Expert Optimizer training

APC and Analytics

Advanced Process Control with ABB Ability System 800xA

References

Examples of APC for grinding and flotation optimization in minerals processing at Boliden mine, Sweden

Examples of APC enabling higher level of automation and optimization of rotary cement kilns and mills, alternative fuel management and material blending

Case study: the use of a digital twin with Advanced Process Control at Boliden Aitik mine

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