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Abstract: This paper presents a novel way of using a dynamic flotation process simulation environment
for concurrent simulation alongside a real flotation process. The simulation environment is actively
adapted to a real flotation process. This yields new possibilities on the usability of the simulation model.
For example, virtual measurements can be introduced that provide completely new variables or increased
fault tolerance through redundancy. Another option is to provide feedback for the process operators in the
form of textual reports. These reports contain e.g. shift-specific performance indices that can be
compared against reference data. Furthermore, by speeding up the simulation, it is possible to make
prognosis on the effects of different control actions before actually making them.
Keywords: process simulators, operators, process models, adaptation, process automation.
SURFHVV LV PRGHOHG ZLWK 2XWRWHF¶V +6& 6LP VLPXODWLRQ kinetics are obtained by model fitting them to the plant circuit
software (see section 2.1) and the process is connected to the sampling data. Calculation of mineral recoveries is based on
automation system via programmable logic controllers compartment model presented by Savassi (2005) in steady
(PLCs), just as in real life. The PLCs are also virtualized by a state form. Description of the applied calculation equations
custom made logic emulator (see Roine et al., 2011). for true flotation, entrainment and froth recovery are
summarized in Roine et al. (2011). True flotation recovery R
(%), with residence time t, for fast-, slow- and non-floating
particles with corresponding flotation kinetic rates (kF, kS and
kNon) and mass proportions of them (mF, mS and mNon) in
steady state is obtained by Equation (1). Here, the recovery
by flotation is calculated dynamically,
4 L srr @I¿
Þ· ç ÞÄ ç
E IÌ E IÇâá Û rA. (1)
5>Þ· ç 5>ÞÄ ç
2.1 Dynamic Flotation Circuit Model 2.3 Adaptation Scheme to Track the Real Circuit Response
The simulation model of the flotation circuit (i.e. the blue Adaptation algorithms are also coded with Matlab®, and are
rectangle in the lower left corner of Fig. 1) was set up as a thus integrated into logic emulation software. Several
property based simulation. It means that the feed material is adaptation approaches have been tested and the most
described with particles, each of them having their own size promising ones are currently under investigation. The results
classes, mineralogy and specific gravities. A brief description reported in this paper are obtained with a simple
of property based simulators for minerals and metals implementation of PID based adaptation. This is a good
processing can be found in Lamberg 2010. starting point for verifying correct operation.
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Fig. 2. Dynamic HSC simulation flowsheet of the Pyhäsalmi copper flotation circuit.
The general idea of the adaptation process is depicted in line laser diffraction analyzer), feed tonnage belt scales, and
Fig. 3, where it is shown that some measurements are merely slurry density transmitters.
fed through the adaptation system. These include, for
In addition, the flotation model parameters are updated based
example, the necessary variables describing the changes in
on the plant measurements to track the key measurements e.g.
the ore flow that is fed to the flotation circuit, as they can be
when the ore type is changing. Each flotation stage in the
used directly in the simulation model. The flotation kinetics
model (Fig. 2) has its own flotation kinetic rates. The
rates, however, do not have a direct physical interpretation
recoveries are tracked based on rougher-scavenger response
(i.e. cannot be measured directly) and thus their values have
to the final tails recovery, by manipulating the kinetic factors
to be estimated indirectly in the Parameter Estimator. The
(kF and kS in Eq. 1) of all flotation stages through the circuit.
parameter estimation concept is covered in detail in Pietilä et
The final concentrate Cu grade (%) is tracked by
al. (2013).
manipulating the pyrite kinetics, since it is the major sulphide
mineral tending to recover to the concentrate, thus affecting
to the Cu grade.
The variable pairings for the adaptation are listed in Table 1.
Still, the calculation of the measured recoveries involves
assays of feed F (%), concentrate C (%) and tails T (%)
streams as follows (Wills and Napier-Munn, 2006),
¼:¿?Í;
4 L srr . (2)
¿:¼?Í;
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the improvement of the simulation model with regard of the Savassi O.N. (2005). A Compartment Model for the Mass
effects of reagent dosage changes. Transfer Inside a Conventional Floation Cell, Int. J.
Miner. Process, 77, pp. 65-79.
Welsby S.D.D., Vianna S.M.S.M., Franzidis J.-P. (2010).
ACKNOWLEDGEMENTS Assigning physical significance to floatability
components, Int. J. Miner. Process, 97, pp. 59-67.
The work reported in this paper is done in the SOREX
Wills B.A., and Napier-Munn T.J. (2006). :LOOV¶ 0LQHUDO
project, which is a part of the Green Mining program funded
Processing Technology, Seventh Edition. Butterworth-
by TEKES ± the Finnish Funding Agency for Technology Heinemann, Oxford, United Kingdom.
and Innovation. The authors would like to thank Outotec Oyj
and Pyhäsalmi Mine Oy for the fruitful collaboration.
REFERENCES
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