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Outotec FrothSense TM

Consistent information for online process control

Traditionally,

flotation

plant

operators

have

had

to

depend on visual assessments of froth appearance

when making operative decisions. As interpretations

between operators can vary greatly from shift to

shift,

this

can

lead

to

inconsistent process results.

The Outotec FrothSense TM system enables the plant to overcome subjective factors in order to provide consistent information 24 hours a day for use by operators, process control and optimization. The FrothSense system measures several essential properties of froth appearance, including froth speed, direction, bubble size, froth stability and froth color, while also providing statistical data related to these variables. The measured froth properties, together with on-stream analyzer assays, allow the creation of efficient and robust strategies for advanced flotation process control by using a system such as Outotec ACT. In addition, FrothSense delivers live video streams from the froth cameras directly to the control room.

Benefits „ Provides consistent information • For use by operators • For process control and optimization
Benefits
„
Provides consistent information
For use by operators
• For process control and optimization
„
Stabilized process
Through the usage of froth properties in process
control
„
Flexible operation
Fully automatic operation
Consistent performance
Convenient monitoring
• Simple installation, operation and maintenance

Outotec FrothSense features

FrothSense is a tool for froth surface analysis providing real-time measurements and statistics of:

  • „ Froth speed and direction

  • „ Bubble size distribution

  • „ Froth stability

  • „ Froth color (RGB and CIE-LAB)

A typical FrothSense installation has several froth imagers mounted on top of flotation machines. The imagers feature an advanced Power over Ethernet (PoE) solution that makes it possible to transmit all data and power for both the camera and the LED lights with just one standard Ethernet cable. The imagers are networked through FrothSense Connection Cabinets to a FrothSense Analysis Server, which runs the necessary machine vision algorithms and acts as an interface to the plant automation network using OPC.

In order to fully utilize the real-time froth analyses, the FrothSense system should be accompanied by Outotec ACT Advanced Process Control system. The ACT system makes it straightforward to control the froth speed of the camera-equipped flotation machines, or even to build a comprehensive grade-recovery system for the optimization of the entire flotation circuit.

Main advantages of FrothSense are:

  • „ High-quality digital network cameras

  • „ Lightweight, allowing easy handling and installation

  • „ Simple cabling – single cable for all data and power for imager and lights

  • „ Central data analysis in FrothSense Analysis Server

In addition to the online analyses of FrothSense, the captured image data can be saved for future inspection. This feature is especially useful in process studies, or if the need arises to develop new algorithms in FrothSense.

FrothSense Imager Assembly

The FrothSense Imager Assembly consists of a high-resolution color camera, controlled LED lighting and a convenient mounting tube. The imager module is designed for flotation plant environments.

FrothSense Connection Cabinet

The FrothSense Connection Cabinet provides a central connection point for up to 16 imagers, featuring both

fiber-optic and copper media connections to the plant network. The system supports virtually any network topology, such as the star or ring configurations. The cabinet is equipped with IP67-rated connectors that eliminate the need for opening the cabinet when connecting cameras. The system is designed for easy maintenance access, having all the power supply units and fuses for the cameras and lights in one convenient place.

FrothSense Server

The FrothSense server is the heart of the operation as

it captures and analyzes the footage delivered by the camera network and publishes the results using an OPC server.

Outotec FrothSense features FrothSense is a tool for froth surface analysis providing real-time measurements and statistics

FrothSense camera image, with no analysis data

Outotec FrothSense features FrothSense is a tool for froth surface analysis providing real-time measurements and statistics

FrothSense camera image, with bubble size analysis. Red lines indicate bubble borders and blue areas indicate the bubble highlights.

Outotec FrothSense features FrothSense is a tool for froth surface analysis providing real-time measurements and statistics

FrothSense camera image, with bubble speed analysis. Individual arrows indicate the speed and direction of the respective regions.

Outotec solution with FrothSense, ACT and Courier for advanced flotation control

Outotec solution with FrothSense, ACT and Courier for advanced flotation control Outotec FrothSense Froth speed &
Outotec solution with FrothSense, ACT and Courier for advanced flotation control Outotec FrothSense Froth speed &

Outotec FrothSense

Outotec solution with FrothSense, ACT and Courier for advanced flotation control Outotec FrothSense Froth speed &
Froth speed & characteristics Control actions Slurry Outotec Courier Analyzer Outotec ACT
Froth speed & characteristics
Control actions
Slurry
Outotec Courier Analyzer
Outotec ACT

FrothSense

Connection

Cabinet

Finland, March 2012.

Outotec FrothSense

Froth Imager Assembly (FIA)

Resolution

pixels

800x600

Material

 

Stainless Steel AISI316 ,Plastic, Coated aluminium

Digital image data type

 

JPEG, H.264, Motion JPEG

Live video stream frame rate

fps

30

IP rating

 

IP66 / NEMA4X

Dimensions

mm

Diameter max 360, Height 860

Weight

kg

9

Operating temperature range

°C

0-45

Humidity

%

5 – 95

Power

 

0 *

FrothSense Connection Cabinet (FCC)

Max. number of imagers per cabinet

 

16

IP rating

 

IP66 / NEMA 4X

Material

 

Painted Stainless Steel AISI304

Cabinet mounting

 

tab (wall mounting)

Enclosure dimensions (Width x Depth x Height)

mm

520x220x600

Weight

kg

25

Connection between imager (FIA) and cabinet (FCC)

 

Ethernet CAT6

Connection between cabinet and server

 

Ethernet CAT6 or Multimode fiber Wireless (Option) 802.11 **

Max. cable length between imager (FIA) and cabinet (FCC)

m

100

Max. total length between imagers (FIA) and single cabinet (FCC)

m

1000

Power

 

110 / 230 VAC, 50/60*** Hz, 340 W

* No external supply needed, powered by FCC ** Option, recommended only with 4 imager units (FIA) or less ***Absolute maximum power. Depends on the number of connected imagers. The technical data is subject to change without notice.

Finland, March 2012. Outotec FrothSense Froth Imager Assembly (FIA) Resolution pixels 800x600 Material Stainless Steel AISI316

Outotec FrothSense is delivered as an operational package containing:

  • „ Froth Imager Assemblies

  • „ Connection Cabinets

  • „ Analysis server

  • „ Software license

Outotec - A lifetime of service

Outotec provides services for the entire lifecycle of your asset, from single pieces of equipment to entire plants. Outotec offers services through a global network of service centers that are committed to providing support whenever needed.

Outotec services are designed to optimize the customers’ plants, equipment and processes. They cover everything from spare parts and maintenance to plant evaluations and upgrades, as well as project management and training.

Finland, March 2012. Outotec FrothSense Froth Imager Assembly (FIA) Resolution pixels 800x600 Material Stainless Steel AISI316

Outotec develops and provides technology solutions for the sustainable use of Earth’s natural resources. As the global leader in minerals and metals processing technology, Outotec has developed over decades several breakthrough technologies. The company also offers innovative solutions for the chemical industry, industrial water treatment and the utilization of alternative energy sources. Outotec shares are listed on the NASDAQ OMX Helsinki.

automation@outotec.com www.outotec.com Copyright © 2012 Outotec Oyj. All rights reserved.

Finland, March 2012. Outotec FrothSense Froth Imager Assembly (FIA) Resolution pixels 800x600 Material Stainless Steel AISI316