Thickeners multivariable predictive control: Division

Codelco Norte
Guillermo Corts
Codelco, Chile

Jaime Cerda
Kairos Mining, Chile
ABSTRACT
The mining industry gives central importance to rational and efficient use of water in their
operations by adopting measures to optimise their consumption through better management practices. For this reason, Honeywells Advanced Control Applications, together
with Codelco Norte, have implemented advanced control strategy in High Rate thickeners.
The advanced control technique used for implementation is the so called Model
Predictive Control (MPC), which aims to drive the continuous process variables under
normal operating conditions.
Profit Controller or Robust Multivariable Predictive Control Technology (RMPCT) is
Honeywells multivariable control and optimisation application for complex and highly
interactive industrial processes. The overall process model is composed of a matrix of
dynamic sub-process models, each of which describes the effect of one of the
independent variables (Manipulated Variables and Disturbance Variables) on one of
the Controlled Variables. A sub-process model describes how the effect of an
independent variable on a Controlled Variable evolves over time.
The strategy objective is Stabilise and govern the process of thickening, maintaining
operational range and ensure proper operation of the thickener. To reach that
objective, the matrix multivariable control solution manipulates the flocculant dose and
opening of the valve-discharge as manipulated variables to keep in range: level
interface, mechanical torque, underflow solid average percent.
The RMPCT will be an effective tool for operations support, helping operators to attain
their own production commitments and to have controlled a process that can take up to
nearly two hours to see a response to a set-point change.
The results obtained with RMPCT respect to manual operation are: (a) Underflow solid
average percent has been reduced by 22.3% in variability but with a similar mean value,
(b) Mechanical torque has been reduced by 35% in variability and 29.2% in mean value,
(c) Level interface has been reduced by 37.57% in variability but with a similar mean
value, and (d) the use of the strategy saves 2.8% of fresh water.

INTRODUCTION
The Concentrator of Divisin Codelco Norte, Chile has nine tailings thickeners, which are used to
thicken the tailings and reclaim water from them. Several control strategies, including expert
control, have been implemented in the thickener, but the results were not satisfactory, therefore the
thickening process continued to run in manual operation.
1

The purpose of this paper is to present what has been the experience and some results obtained
when implementing a new control approach. This paper is structured as follow. Section describes
the thickening process and the available equipment. The control objective is shown in Section 2.
The control approach is described in Section 3 while Section 4 presents different aspects of the
implementation. Results and discussions are presented in Section 5. The paper finalises with the
conclusions as presented in Section 6.
PROBLEM STATEMENT
This section presents a brief description of the thickening process as well as the available measurements
of the variables and control loops to be used for implementing advanced control strategy. It also include
a brief description of the operational parameters and the purpose of the control system.
Thickening process
The concentrator at Division Codelco Norte, has nine Tailings thickeners, which are used to thicken
the tailings and reclaim water from them. The T7 and T8 thickeners have a diameter of 325 are a
high-tech edited capacity by Door Oliver with a processing capacity of 50904 TMSD with a drive
unit to withstand a torque of 4800 Klbs-ft.
The High Rate Thickener is a cylindrical-conical tank; its function is to reclaimed water from the
tailings of the flotation process. The thickener has a canal of incoming feed, a central ring, a system
of central drive rake, a peripheral canal to retrieve clear water and three solid discharges in the
centre bottom of the thickener, as shown in Figure 1.

Figure 1 High Rate Thickener: Side view and top view

Feeding sinks before reaching the centre ring of feed (feedwell) and injected with a nozzle, the clear
water of the surface of the thickener is absorbed by Venturi effect which dilutes the pulp fed. In
feedwell, the feed is separated into two tubes where flocculant is added in four points to each tube,
to stimulate flocculant / pulp mixture and thus enhancing the flocculation of the solids fed.

The solids settle to form a bed, with solids concentration increasing towards the underflow at the
base. Clarified water is collected at the peripheral overflow, while a centrally driven rake promotes
consolidation and assists sediment transport to the underflow.
The rake system consists of two primaries and two secondary rakes, with a hydraulic mechanism of
central traction. The rakes assist in dewatering sediment within the thickener bed and moving
slowly so as not to cause turbulence and to transport the sedimented material to underflow in the
centre of the conical bottom.
Control loops and measurements
Figure 2 depicts a diagram of the High Rate Thickener 7 with the available measurements and
control loops.

Figure 2 Control diagram of high rate thickener T7

Flocculant adding
The flocculant addition is proportional to the tonnage treated in the thickener (calculated using the
measurement of flow in the canal and assuming a percentage of solids in the tailings measured by
sampling food or laboratory) and water is added to the flocculant pipe in proportion to the flow of
flocculant.
Measuring Water-pulp interface
In all tailings thickeners measurement of pulp-water interface is done by a sonic sensor immersed
type supported on the bridge of the thickener.

Underflow Solid average percent

Each discharge line has density measurement using nuclear density meter and a control valve type
"muscle" with hydraulic actuator with optional remote operation of DCS, which allows adjusting the
discharge flow. Hydraulic units for muscle valves are in the "Hydraulic Room", which also contain
instrumentation panels and density transmitters. Remote operation of the valves is satisfactory.
In the High-Rate Thickener T7, the opening and closing of a valve cutting is done by a hydraulic
actuator operated locally and fed by a hydraulic unit with quick coupling system allowing you to
use the same hydraulic unit to operate the three valves knife.
Reclaimed water
Reclaimed water from the thickeners, obtained by overflow, drain to a peripheral channel, then
leads to a rectangular canal by passing it through a sinkhole. Then it is transported to a pumping
station to return it to the grinding plant. There is no measurement of flow in reclaimed water
collecting gutters which implies mass balances in imprecisely.
Operational parameters
The operational parameters of the High Rate Thickener T7 are:
Mechanical torque: Less than 30% of the Nominal torque
Flocculant dose: 2 grammes / ton to 4 g / t Normal, 6 grammes / Ton Max
Discharge flow: According to the% solids to be taken, it must maintain balance, so that
what goes in equals what comes out
Level interface: 1.6 to 2.0 metres
Underflow Solid average percent: 58-60% according to design
Pulp flow: 2985-5220 m3/hr.
Food tonnage TMSPH: 1500@38.4% solids by weight, Max.
Process control objective
The principal issue in the thickeners is related to the type of control loop used for the operation.
This is illustrated for the typical actions executed by the operator: the operator entered a setpoint for
the flocculant dose, % average discharge opening and he waited one or two hours to see the
responses in the Underflow Solid average percent, the leel interface and the mechanical torque.
These responses could show errors and a not desired behaviour. From this illustration it is clear that
this multivariable process operated in open loop; and it was not possible to rectify any error that
could be present. It could not also compensate for the effects of disturbance in the system
Therefore, to stabilise the process and guarantee a proper operation of the thickener it was
necessary to modify the control approach where the process control objectives are:
Reduce the standard deviation of % underflow solids and mechanical torque
Keep the equilibrium condition of the thickener
Reject the effect of disturbances originated in the upstream milling and flotation process
Prevent high torque in the rake
Keep the Differential Inventory Accumulated Charge into a range
4

The feasible control strategy should satisfy the objectives stated above, if that objective cannot be
reached directly it should, at least, point even indirectly and implicitly to it.
The use of the controller will reduce the standard deviation of critical control variables, which will
improve the performance of thickener, maximise the Underflow Solid average percent, keeping the torque
controlled without to damage the thickener. Indirectly the controller will improve reclaimed water.
Advanced control strategy selection
Thickener application has been implemented using technology called Profit Controller; this is a
Multivariable Predictive Control algorithm based on models. This tool incorporates a dynamic model of
the process, comprising a transfer function matrix. This controller, by knowing the future behaviour of
the controlled variables (inputs to the controller), can determine the best set of values of the manipulated
variables (controller outputs), which are sent as set points to the PID controllers used in the process.
Figure 3 depicts the MPC scheme, where k is the current time, H is the time horizon, CV and MV stand
for the input and output variables, respectively. At current time k, based on the model of the plant, a
sequence of the optimal control inputs MV(k), MV(k + 1), ..., MV(k + H) is computed by solving an
optimisation problem over the prediction horizon H meanwhile satisfying input and output constraints.
But only the current one is applied to the plant. The optimisation is repeated in each time point, i.e. k +
1, k + 2, .. until CV(k) reaches the High Limi.(For this case, where High Limit is the optimal).

Figure 3 MPC scheme

For this reason we have selected a Multivariable Predictive Control (MPC), which contains a
structure that allows effective management of interactions of the process thus enabling its action to
reduce the variability of the operation, given the greater capacity of governance the process.
These are control algorithms that use an explicit process model to predict the future plant response.
According to this prediction in the chosen period, also known as the prediction horizon, the MPC
algorithm optimises the manipulated variable to obtain an optimal future plant response. The input
of chosen length, also known as control horizon, is sent into the plant and then the entire sequence
is repeated again in the next time sample.

IMPLEMENTATION PHASES
The methodology for the implementation of a controller has three important phases that can be
recognised during implementation; viz. Test Protocol, Model Identification and Controller
Implementation.
Test protocol
Process model identification is based on input/output performance data, generated by test signals.
Test signals are required to excite both steady-state (low frequency) and dynamic behaviour (high
frequency). Test protocol is then the most important task during the implementation of a
multivariable controller. Most of the implementation time is consumed during the data generation
task. In this context selecting the best signal generator is an important decision, in order to provide
rich data for the identification phase.
In this sense there is a need to select the signals providing the largest power spectrum (rich in
frequency) in order to provide a good data set for identification. Because of its power spectrum
features, PRBS (Pseudo Random Binary Sequence) is recommended to be used as signal generator
rather than step or ramp signals as shown in Figure 4. To prepare a formal plant test, a pre-test is
usually necessary for the following reasons:
Improve instruments calibration and filtered signal
Evaluate PID performance for each MV(Manipulated Variable)
To obtain steady state time for each CV(Controlled Variable)
To obtain models and relationship for each DV(Disturbance Variable)
To obtain settling time
To obtain data for initial identification

Figure 4 Profit Stepper system

Model identification
A fundamental problem for any controller is the choice of the model that should be used to represent
the system. In general, the model is one of the following: Linear time-invariant (lumped parameter),
Linear time varying (lumped parameter), Linear with distributed parameters or Nonlinear.
6

System identification remains both an art and a science. The science is concerned with parameter
estimation; the art is usually concerned with determining structure/order, the excitation
requirements, and accuracy. System identification involves two steps. First, a sequence for exciting
the process to be modelled is specified. A family of candidate models is then proposed. After this a
representative member of this family is selected. The second step is a parameter-estimation
problem. Parameter estimation is basically the determination of the best set of candidate model
coefficients such that the model represents the causal input/output relationships.
The identification process is executed in PDS that provide a Matrix of models; each sub model
represents the dynamic relationship between MV/DV and all CVs affected. Because all sub models
are linear and time-invariant, superposition principle applies. The obtained models are used by the
controller in order to predict the behaviour of CVs. Profit Controller calculates the actions needed
to drive back each CV into its control range. The generated MV actions are based on the following
optimisation criterion:
2
(1)
min u, y W ( Au y real ) ,
Subject to:

ROC min u ROC max (ROC Rate of Change of MV within ROC limits)
MVmin u MVmax
CVmin y CVmax

(MVs lie within high and low bounds)

CVs must lay within high and low bounds)

where, y (the Predicted CV) can be represented as:

Au

where A is the process model and u is a set of MV moves. The solution u is the control action and
the solution y is the optimal CV response trajectory.
Control strategy implementation
The advanced control strategy of a thickener process has to achieve the following performance
objectives: (1) safety/operation constraints; (2) reducing the standard deviations of controlled
variables; (3) de-bottlenecking the process; and (4) maximising product value (or profitability). The
objectives are prioritised in this same order, but the order can vary from operation to operation
within an application.
We use step response modelling for the MPC controller, proven to be effective in Profit Controller
applications. Step response modelling makes prediction of process outputs available explicitly. Future
prediction is used to compute the predicted error vector as an input to the MPC controller. We can
consider future process output as a process state and use modified state space for process modelling.
Profit Thick is the model of the thickener with Profit Controller technology. The variables of the
model are:

CV- Controlled variables: Mechanical Torque, Differential Inventory Accumulated

Charge, Underflow Solid average percent, and Level Interface
DV- Disturbance variable: Pulp Volumetric Flow discharge
MV- Manipulated variables: Flocculant dose and % Average Discharge Opening

Figure 5 shows the matrix of relationships proposed for this controller and Figure 6 shows the
configuration parameter for the Step Test.
MV1:
Flocculant dose

MV2: % Avg.
Discharge
opening

DV1: Pulp
volumetric flow
discharge

Range

[4-5] grs/Ton

[0-100] %

[4500-5500]m3/hr

Step size

1 gr/Ton

15%

N/A

Settling Time
Max
Settling
time

Figure 5 Expectations matrix

2,5 hours

Min Settling
Time

1 hour

Figure 6 Parameter configuration for the Step Test

Figure 5 can be used to investigate the expected effect on the Output Variables CVs due to the
different changes in the Manipulated Variables (MVs):
Flocculant dose [grs. / Ton]: The expected effect of flocculant is increased sedimentation rate
by the group of "floc" that will carry the load compaction zone in a shorter time. The most
likely outcome of this effect is a pulp with higher % solids, an increased height of clear water, a
higher value of torque.
% Average Discharge Opening [%]: The expected effect in Underflow of the thickener is the status
of "relief" from the thickener. If the Underflow solid average percent, Mechanical Torque or
Differential Inventory Accumulated Charge is too high, the % average discharge opening is sped up
to increase the removal rate of slurry from the thickener. If the Underflow solid percent, Differential
Inventory Accumulated Charge or Mechanical Torque is too low, the reverse action occurs.
Figure 7 Show the different MVs, CVs, and DVs relation with Profit Thick Strategy.

Figure 7 Profit Thick strategy

RESULTS AND BENEFITS

Evaluation conditions
Profit Thick T7 controller assessment was conducted during the months of April and May 2010.
The evaluation process consisted in a series of ON/OFF tests. During this period the thickening
process operates for four days with Profit Controller and four days without it. Well defined
protocols were used to establish the operating conditions for the test, so similar conditions were
defined for the operation: Profit Thick ON and Profit Thick OFF. These conditions are:
Feed volumetric flow >= 4000 m3/hr
Low Limit Underflow solid average percent > 57 %
High Limit Underflow solid average percent < = 60 %
Flocculant dose >= 4grs/Ton
Operators involvement
User involvement was present throughout the implementation process of Profit Thick T7
applications and during all development stages. Constant contact with operation personnel has
enabled to satisfy operator needs with the continuous improvement of the applications.
This task participation was highly relevant on the results obtained and improved in time, especially
on the high application use.
Strategy utilisation
Since applications were delivered to operation, they achieved mean utilisation of 96.1%. Their
monthly usage in normal months is larger than 95%, as shown Figure 8 and Table 1.

Table 1 Profit Thick usage

Month
Oct-09
Nov-09
Dec-09
Jan-10
Feb-10

% usage
99.7
95.3
96.2
96.1
maintenance

Month
Mar-10
Apr-10
May-10
Jun-10
Average
usage/month

% usage
92.9
100.0
88.4
100.0
96.1

Figure 8 Usage Profit Thick T7

Stability improvement using Profit Thick

The results obtained with RMPCT respect to manual operation are:
Movement of the % discharge opening average has been reduced in 56% in variability as
shown in Figure 9
The Underflow solid average percent has been reduced by 22.3% in variability but a similar
mean value as shown in Figure 10
9

Mechanical torque has been reduced by 35% in variability and 29.2% in mean value as
shown in Figure 11
Level interface has been reduced by 37.57% in variability but with a similar mean value as
shown in Figure 12

Figure 9 Histogram of changes in % discharge opening Profit OFF vs. Profit ON

Figure 10 Histogram of Underflow solid average

percent Profit OFF and Profit ON

Figure 11 Histogram of Mechanical torque in the rake

Profit OFF and Profit ON

Figure 12 Histogram of level interface Profit OFF Profit ON

For example, if you increase to 59.5% of solid in the Underflow solid average percent. This could
be possible because:
The Underflow solid average percent can be raised, due to solid improvements in the
standard deviation
The improvements gained through the reduction of the standard deviation of the mechanical
torque and the level interface that were observed during testing.

10

Increasing from 59% to 59.5% the Underflow Solid average benefits the process by reducing the fresh
water consumption in 2.8% per each Thicks High Rate. But this must be confirmed by Plant Test.
CONCLUSIONS AND BENEFITS OBTAINED
Profit Thick has been a successful implementation approach, teaming-up with plant personnel.
The strategy acceptance from plant operators is reflected in the large operating availability, shortly
achieved.
The analysis shows a statistically significant improvement when using Profit Controller in the
process of thickening for the values of the standard deviations of Torque and Level Interface.
The use of Profit keeps variables process within established ranges. First continuously manipulates
valves discharge with smooth movements and ultimately manipulate the flocculant dose, which is
very suitable for the treatment of ore in unfavourable conditions.
This allows working with a higher average boundary for Underflow Solid average percent because the
variability has been reduced, operating with smoother movements average discharge opening valve. It
is recommended to implement this control strategy in all the thickeners of the concentrator because
the expected benefits are to increase by 0.5% the Underflow Solid average percent in the thickener
which represents 2.8% of water used by the Concentrator for processing per day for each Thick.
NOMENCLATURE
Q = T x (D1 - D2)
Q = Flow of water m3/day
T = Tonnage of tailings thickener Ton/day
D1 = Dilution of the pulp in the thickener feed
D2 = Dilution of the pulp in the of thickener
Dilution = (100 - Underflow Solid average percent) / Underflow Solid average percent
Controller OFF
D1 = (100 - 38) / 38 = 1.632
Controller ON
D3 = (100 59.5) / 59.5 = 0.6807
D2 = (100 - 59) / 59 = 0.695
Q2 = T x (D1 - D3)
Q1 = T x (D1 - D2)
Q2 = 170000 x (1.632 0.681)
Q1 = 170000 x (D1 D2)
Q2 = 161670 m3/day
Q1 = 159290 m3/day

Therefore, increasing from 59% to 59.5% the Underflow Solid average percent to the same
conditions. The flow of water is:
Q2 - Q1 = 161670-159290 = 2380 m3/day.
The use of fresh water is 0.5 m3 per tonnage of ore processed. Profit Thicks saves 0.028 m3 fresh
water per Ton procesed, i.e. 2.8% saves fresh water per each Thicks High Rate.

11