BENEFICIATION PROCESS CONTROL
An overview of
Flotation Process Control
INTRODUCTION
• Flotation is a multiphase, probabilistic, interactive, physiochemical
process. Flotation performance can be predicted by combining all
the probabilistic events.
• Flotation is carried out when minerals are finely disseminated. It
requires very fine grinding for liberation. All other beneficiation
processes turn out techno-economically non viable. Even flotation
becomes complex at finer sizes.
• Flotation is carried out in several flotation cells/banks which may
be in parallel. They include many recirculation streams and
complexity of the process increases.
• Because of the complexities, it was very difficult to control the
flotation process to obtain desired performance with inherent
fluctuations and variation in process variables. So automated
control systems with artificial intelligence are now adopted.
A TYPICAL FLOTATION CIRCUIT
p
T H AIR
FEED
GRINDING CONDITIONER
p
H
REGRIND
SO2
A
COLLECTOR
A
Na2CO3 & MODIFIER
ROUGHER
SCAVANGE
A MODIFIER R
TO CLEANER A
TAILING
T TONNAGE A ASSAY
Fig. Important Measured and Control Variables
FLOTATION PROCESS VARIABLES
• Volumetric flow rate of slurry – Rota meter / motor current mapping
• Percentage solid of the feed pulp – Online measurement & control
• Pulp pH – (pH meters : controller)
• Aeration rate – (Pressure Gauge : controller)
• Pulp level – (Sensor : controller)
• Chemical assays of feed and products - (on stream analyzers)
• Selection of specific reagent and its quantity – Manual/ Automated
For process control, we have to control all important process variable
using fully automated or semi-automated instruments.
GENERAL ASPECTS OF CONTROL
• Run the system at predefined (optimum ) values of the process
variable. Some inherent fluctuations in feed rate can be controlled
by installing surge bins prior to process unit to give a fixed flow
rate.
• Controllers have a predefined set points and process variable are
kept at those levels.
• Run the control systems coupled with simulators. Sensors send data
to simulators. Simulators estimates optimum values of the process
variables and sends it to controllers. Controllers do the action to
keep the variable at the level of new set point.
• Major drawback of second approach is time lag between sensing,
estimation and execution. Desired results may not be obtained in
case of rapid fluctuations.
A TYPICAL PULP LEVEL CONTROLLER
SENSOR MONITOR CONTROLLER
FROTH
CLARKSON FEEDER
FROTHER
PULP
Fig. Pulp Level Measurement in Flotation Cell
GUIDELINES FOR LABORATORY TEST WORK
Conventional : Decrease in
Constant pulp level
pulp level with time
ON STREAM X-RAY ANALYZER
For any flotation control problem, primary requirement is an
instrument which can measure the assays of sample from critical
stream in a continuous system.
On Stream X-ray Fluorescence Analyzer is one of the most
sophisticated assay analyzer.
Feed Sample Thief
Concentrate
On stream X- ray
Analyzer
Tailing Assay Values Pulp Density
How X-Ray Fluorescence Analyzer works?
• High energy X-ray radiation is used to excite the elements. A
radiation of certain wavelength is absorbed by a specific
element. From the difference between input radiation intensity
and detected by sensor after absorption is used to estimate
concentration of that particular element.
• The wavelength pattern is generated by detector and pulse
counts are converted into digital signals. This signal is mapped
with calibrated patterns. Based on the calibration based on
multi-element regression equation assays are estimated.
• Typical controllers soft wares are:
PROSCON 103, and PROSCON 105.
SALIENT FEATURES OF ON STREAM ANALYZERS
• Time lag between sampling to control action should be
minimum.
• Accuracy of the measurement is very critical. A minute error
in control action may result in surplus losses.
• Sampling procedures should be such that contamination does
not take place because of the previous samples.
• All the sensors work on the principal of mapping and
calibration. It should be done with data prolonged over entire
range. Extrapolation of calibration curve will result in more
errors.
CONTROL ALGORITHM (PROSCON 103)
ACTION CONTROLLER
SENSOR OPERATOR’S CONSOLE
SAMPLE
THIEF
ANALOG SIGNAL
MESCON PROCESS INTERFACE
PROCESS DIGITAL SIGNAL
STREAM
PROCESS COMPUTER
DISPLAY MONITOR
THANK YOU !!!
