Proceedings, 5th IFAC Workshop on Mining, Mineral and Metal

Proceedings,
Processing 5th IFAC Workshop on Mining, Mineral and Metal
Proceedings,
Proceedings, 5th
5th IFAC
ProcessingChina,
Shanghai, IFAC Workshop
Workshop
August on
on Mining,
23-25, 2018 Mining, Mineral
onlineand
Mineral
Available and Metal
Metal
at www.sciencedirect.com
Proceedings,
Processing
Proceedings,
Processing 5th
5th IFAC
IFAC Workshop
Workshop on
on Mining,
Mining, Mineral
Mineral and
and Metal
Metal
Shanghai, China, August 23-25, 2018
Processing
Shanghai,
Shanghai, China,
ProcessingChina, August
August 23-25,
23-25, 2018
2018
Shanghai, China,
Shanghai, China, August
August 23-25,
23-25, 2018
2018
ScienceDirect
IFAC PapersOnLine 51-21 (2018) 111–116
Adapting a Phenomenological Model of a Rougher Flotation Circuit to Industrial
Adapting a Phenomenological Model
Historical of a Rougher
Operating Data Flotation
Base Circuit to Industrial
Adapting a Phenomenological Model
Historical of a
OperatingRougher Flotation
Data Flotation
Base Circuit to Industrial
Adapting a Phenomenological Model of a Rougher Circuit to Industrial
Historical Operating Data Base
Historical
L. Bergh*, Operating
J.Yianatos*, Data
C. Acuña*, Base
K. Inostroza*
L. Bergh*, J.Yianatos*, C. Acuña*, K. Inostroza*
L. Bergh*,
L. Bergh*, J.Yianatos*,
J.Yianatos*, C.
C. Acuña*, K.
 Acuña*, K. Inostroza*
Inostroza*
L.Chemical
* Department ofL. Bergh*, Engineering,
Bergh*, J.Yianatos*, Santa
J.Yianatos*, C.
C. Acuña*, K.
Maria K.
 Acuña*, Inostroza*
University, Valparaíso, Chile
Inostroza*
* Department of(Tel:
Chemical Engineering,
56-32-2654229; Santa

e-mail: Maria University,
luis.bergh@ Valparaíso, Chile
usm.cl).
** Department
Department of Chemical
of(Tel:
Chemical Engineering,
Engineering, Santa Maria
Maria University,
Santaluis.bergh@
University, Valparaíso,
Valparaíso, Chile
Chile
** Department 56-32-2654229; e-mail: usm.cl).
Department of Chemical
of(Tel:
Chemical Engineering,
Engineering,
56-32-2654229; Santa
Santa
e-mail: Maria
Maria University,
University,
luis.bergh@ Valparaíso,
Valparaíso, Chile
usm.cl).
(Tel: 56-32-2654229; e-mail: luis.bergh@ usm.cl). Chile
(Tel: 56-32-2654229;
(Tel: 56-32-2654229; e-mail:
e-mail: luis.bergh@
luis.bergh@ usm.cl).
usm.cl).
Abstract: The use of simulators is a powerful tool to train plant operators and to be also incorporated in
Abstract:
the development The useand of simulators is a powerful
test of supervisory tool to
control train plant
strategies. operatorsthe
However, andphenomenological
to be also incorporated models in
Abstract:
Abstract: The
The use
use of
of simulators
simulators is
is aa powerful
powerful tool
tool to
to train
train plant
plant operators
operators and
and to
to be
be also
also incorporated
incorporated in
in
the development
describing
Abstract: the use
The use and
process test of
of simulators
simulators supervisory
areofrelatively
is aa powerful
powerful control
complex, strategies.
toolcharacterized
to train plant
plantHowever,
by nonlinear
operators the phenomenological
relationships
andphenomenological
to be also models
and models
also incorporated
incorporated whose in
Abstract:
the
the The
development
development of
and
and test
test of is
supervisory
supervisory tool
control
control to train
strategies.
strategies. operators
However,
However, and
the
the to be
phenomenological models in
describing
parameters
the the
developmentare process
depending
and test areof
test onrelatively
many local
supervisory complex, factors,
control characterized by plant
such as, However,
strategies. the
However, nonlinear relationships
configuration,
the phenomenological the and whose
individual
models
the development
describing
describing the
the and
process
process areof
are supervisory
relatively
relatively control
complex,
complex, strategies.
characterized
characterized by nonlinear
by plant
nonlinearthe phenomenological
relationships
relationships and
and models
whose
whose
parameters
characteristics
describing are
the ofdepending
the
process on
equipment,
are on many
the
relatively local
availability
complex, factors,
of such
on-line
characterized as, the
measurements
by plant
nonlinear configuration,
and the the
characteristics
relationships individual
and of the
whose
describing
parameters
parameters the
are
are process
depending
depending are onrelatively
many
many complex,
local
local factors,
factors, characterized
such
such as,
as, by
the
the nonlinear
plant relationships
configuration,
configuration, the
the and whose
individual
individual
characteristics
feed, among
parameters are ofdepending
others. the equipment, on the availability
many local of on-line
factors, such measurements
as, the plant and the characteristics
configuration, the of the
individual
parameters
characteristics
characteristics areof ofdepending
the
the equipment, on many
equipment, the local factors,
the availability
availability of
of on-line such as,
on-line the plant configuration,
measurements
measurements and
and the the individual
the characteristics
characteristics of
of the
the
feed, among others.
characteristics of the equipment, the availability of on-line measurements and the characteristics of the
characteristics
feed,
feed,
In among
among
this work, of
others.
others. the
the equipment,
previously the availability
developed of on-line
phenomenological measurements
model is and the
adapted characteristics
to the of
particularthe
feed,
feed,
In among
among
this work, others.
others.
characteristics
In this work, ofthe
the
previously
the rougher
previously circuitdeveloped
developed
phenomenological
of an industrial
phenomenologicalflotation plant, model
model
is adapted
considering
is
to the layout
its particular
adapted to the
particular
and
particular
In
the this work,
characteristics
available of the
the
information previously
rougher
to circuit
feed developed
the of an
simulator. phenomenological
industrial
The flotation
rougher model
plant,
circuit is
considering
consists of adapted
threeits to
particular
lines of the 8 particular
layout
mechanical and
In
In this work,
this work,of the previously developed phenomenological model is adapted to the particular
characteristics
characteristics
the
cellsavailable ofthethe
the
information
previously
rougher
rougher
of to
circuit
circuit
feed
developed
of
of an
the simulator.
phenomenological
an industrial
industrial
The rougher
flotation
flotation model
plant,
plant,
circuit
is adapted
considering
considering its to the layout
its particular
particular particular
layout and
and
the processing
characteristics
characteristics
available ofa the
of feedrougher
the
information 4000
rougher
to tons/h.
circuit
circuit
feed the of an
of an industrial
simulator.industrial
The flotation
flotation
rougher plant,consists
plant,
circuit considering
considering
consists
of three
of threeits lines
its
of 8 mechanical
particular
particular
lines of layout and
layout
88 mechanical and
the
cells available
processing information
a feed of to
4000feed the
tons/h. simulator. The rougher circuit consists of three lines of mechanical
the
the available information to feedtons/h.
the simulator.
simulator. The rougher rougher circuit consists
consists of of three
three lines
lines of of 8 8 mechanical
mechanical
Theavailable
cells
cells
cells
processing
processing
new model
processing
information
a feed
of to
aa predictions
feed
feed of
of
4000
4000
4000
feed the
tons/h.
were
tons/h. tested for The a family of circuit feed characteristics, including variation of
cells
The processing
new model
mineralogical a feed
species of
predictions4000
under were tons/h.
different testedoperating
for a family of feed Since
conditions. characteristics,
some variables including are variation
commonly of
The
The new
new model
model predictions
predictions were
were tested for
testedoperating
fordata aa family
family of
of feed characteristics,
feed Since
characteristics, including
including variation
variation of
of
mineralogical
unmeasured
The new new model
model species
during the under
operation,
predictions different
were additional
testedoperating
for aa familywere
family conditions.
incorporated
of feed
feed Since to some
improve
characteristics, variables
the model
including are commonly
predictability.
variation of
The
mineralogical
mineralogical predictions
species
species under
under were
different
different tested for
operating of
conditions.
conditions. characteristics,
Since some
some including
variables
variables are
are variation
commonly
commonly of
unmeasured
The use of the
mineralogical during
speciesthe operation,
simulator is illustrated
under additional
different data examples,
in operating
several were incorporated
conditions.as wellSince ato improve
discussion
some the model
of the modelpredictability.
prediction
mineralogical
unmeasured
unmeasured species
during
during the under
the operation,
operation, different
additional
additional operating
data were
data examples,
were conditions.
incorporated
incorporated Since to some variables
improve
todiscussion
improve variables
the
the model
model
are
are commonly
commonly
predictability.
predictability.
The use of due
limitations
unmeasured the simulator
to
during some
the is illustrated
particularities
operation, in several
found
additional in
datathe werehistorical as well ato
operating
incorporated data.
improve of the
Copyright
the  model
model 2018 prediction
IFAC.
predictability.
unmeasured
The
The use use of
of due during
the
the the operation,
simulator
simulator is
is illustrated
illustratedadditional
in
in severaldata examples,
several were incorporated
examples, as
as well aatodiscussion
well improve the
discussion of model
of the
the  model
modelpredictability.
prediction
prediction
limitations
The use of the to some particularities
simulator is illustrated found
in in theexamples,
several historical as operating
well data. Copyright
aa discussion of the 2018 IFAC.
The use of the simulator is illustrated in several examples, as well discussion of the  model
 model prediction
prediction
© 2018, IFAC
limitations
limitations
Keywords: due
due to some
(Internationalparticularities
to someflotation,
modeling, Federation
particularities
industrial, found
found in
of Automatic the historical operating
Control) Hosting
in the historical operating data.
bydata.
ElsevierCopyright
Ltd. All
Copyright 2018
rights
2018 IFAC.
reserved.
IFAC.
limitations
Keywords: due
limitations due to
to some
modeling, particularities
someflotation,
particularities
industrial, found
found in in the
the historical
historical operating
operating data. Copyright  2018
data. Copyright 2018 IFAC. IFAC.
Keywords: modeling, flotation,
Keywords: modeling, flotation, industrial, industrial, 
Keywords: modeling,
Keywords: modeling, flotation,
flotation, industrial,
industrial, 
1. INTRODUCTION (ii) The nature of the data used for the modeling
 (ii) The nature of the data used for the modeling
1. INTRODUCTION  (ii)
1.
1.
Big INTRODUCTION
INTRODUCTION
data is a current word across almost all businesses and (ii) (iii)The
(ii) Thenature
The
The
nature
regression
nature
of
of the
of the
data
data used
themethod
data usedfor
used
used
fortothe
for
the
build
the
modeling
modeling
the model
modeling
1.
1. INTRODUCTION
INTRODUCTION (ii)
(iii)The
The nature
regression of the data
method used
used forto the
build modeling
the model
Big
plays data
a key is a current
part word
in Industry across
4.0. Thealmost all
termallbig businesses
data is used and (iii) The regression method used to build the model
Big
Big data
data is a current
is apart
current word
word across
across almost
almost allbig businesses
businesses and
and (iii)
From Thean regression
objective method
point used
of view,to build
there thearemodel
basically two
plays
here
Big toa characterize
data keyis a in data
current Industry
word that 4.0.
is
acrossnotThe
just
almostterm
large
all but data is used
complex
businesses in
and (iii)
(iii)
From The
Thean regression
regression
objective method
method
point used
used
of view,to
to build
build
there the
the model
model
are basically
Big data
plays aa key
plays is a
key part current
part in word
in Industry
Industry 4.0. across
4.0. Thealmost
The term all
term big businesses
big datadata is is usedand
used major From an classes
an objectiveof models:
objective point those
point of to
of view, be
view, there used for
there are passive
are basically use two
basically and
two
here
nature
plays toa(MacGregor,
characterize
key part in data
2017).
Industry that is
4.0.notThe
Furthermore,justterm
large
there bigbut
is complex
not
data just
is one
usedin From major classes of models: those to be used for passive use two
and
plays
here to
here a key part
to characterize in
characterize data Industry
data thatthat is4.0.
is not The
not just term
just large big
large but data
but complex is
complex in usedin From those
From to
an
an be used
objective
objective for active
point
point use.
of
of Passive
view,
view, there
there models
are
are are intended
basically
basically two
two
nature
issue
here (MacGregor,
towith big data, data
characterize 2017).
therethat
data Furthermore,
are
that isdifferent therebut
just objectives
not just large is not just one
depending
complex in major major classes
classes of of models:
models: those those to to be
be used
used forfor passive
passive useuse and
and
here
nature to characterize
(MacGregor, 2017). is not
Furthermore, large
there but
is complex
not just onein those
to
major to be
passively
classes used
observe for
of models:
models: active
the use.
process
those Passive
in
toPassive the
be used models
future.
usedmodels are
Such
for passive
passive intended
passive
use and
and
nature
issue
upon (MacGregor,
with big
whether data,
one 2017).
thereis Furthermore,
are
in different
sales, there is not
objectives
marketing, just
depending one major
finance, those
those classes
to
to be
be used
usedof for
for active
activethose
use.
use. to be
Passive for
models are
are use
intended
intended
nature
nature
issue (MacGregor,
(MacGregor,
with big data, 2017).
2017).
there Furthermore,
Furthermore,
are different there is
there
objectives is not
not just one
just
depending one applicationsto passively
those to be observe
include
used for the process
classification,
active use. ininferential
Passive the future.
models orSuch passive
soft intended
are sensors,
intended
issue
upon withwith big
whether data,
one there are
isthere different
in are sales, objectives
marketing, depending
finance,
to be to those
to to be
passively
passively used
observe for active
the use.
process
observe classification,
the For
process Passive
in the models
future. are
Such passive
manufacturing,
issue
issue
upon with big
whether etc.
big data,
data,
one and
there
thereis are
are
in many objectives
different
different
sales, different
objectives
marketing, issues
depending
depending
finance, applications
and process include
monitoring. suchin the future.
inferential
inpassive usesorSuch
one passive
soft does
sensors,
not
upon
solved
upon
whether
manufacturing,
(data
whether
one
etc. and is
collection,
one there
is
in
in aresales, marketing,
many different
warehousing,
sales, issues
integration,
marketing,
finance,
toand
finance, be to to passively
passively
applications
applications
and process
observe
include
monitoring.
the
the process
observe classification,
include process
classification,
For such
in the
the future.
future.
inferential
inferential
passive uses
or
or
Such
Such
soft
soft
one
passive
passive
sensors,
sensors,
does not
upon whether
manufacturing,
manufacturing, one
etc. and is
there in aresales,
many marketing,
different issuesfinance,
to be need causal
applications models,
include rather
classification,one wants
inferential to just
or model
soft the
sensors,
solved
analytics).
manufacturing,
manufacturing,
solved Mostetc.
(data
(data etc.
etc.
and there
collection,
of these
and
and
collection, there
there
areneed
are
are
many
warehousing,
issues many
many
warehousing, to bedifferent
different
different
issues
integration,
improved issues
issues
integration,
toand
in order
to
toand
be applications
be
be
and
and
need
normal
process
process
causal
include
monitoring.
monitoring.
models,common
variations
classification,
For
For such
rather such
oneto
inferential
passive
passive
wants
the
uses
touses
or one
operating
soft does
justone
sensors,
does
model
not
not
the
process.
solved
analytics). (data
Most collection,
ofthe
these warehousing,
issues need to integration,
be improved and and
in order and
need process
process
causal monitoring.
monitoring.
models, For
rather such
For suchone passive
passive
wants touses
uses
justone does
onemodel not
does notthe
to be
solved
solved able
analytics). (data
(datato
Most use data
collection,
collection,
of these to extract
warehousing,
warehousing,
issues need actionable
to be information.
integration,
integration,
improved in and
and need
order need
normal causal
Historical models,
variations
datamodels,
is ideal rather
common one
for building to wants
the
such to just
operating
models. model the
process.
Models for
analytics).
to be able Most
to use of these
the data issues
to need
extract to be improved
actionable in order
information. need
normal causal
causal models,
variations rather
rather
common one
oneto wants
wants
the to
to just
just
operating model
model the
the
process.
The focus
analytics).
analytics).
to be
be able
able toin this
Most
Most
to use paper
of
of
use the these
these
the datais on
issues
issues
data to the issues
need
need
to extract to
tothat
be
be
extract actionable one
improved
improved must
actionable information. consider
in
in order
order
information. normal normal
Historical
active usevariations
data
are is ideal
intendedcommon
for building
to be to used the
such to operating
models.
actively process.
Models
alter for
the
to
The focus intothis paper is ontothe issues thathow one we must consider Historical variations
normal variations
data is is ideal
idealcommon
common
for building
buildingto
to such the
such operating
the models.
operatingModels
models. process.
process.
Models for
to
to effectively
be
be
The focusable
able
focus in to extract
use
use
in this the
the
this paper
paper is information
data
data
is on to
on the extract
extract
the issues and
actionable
actionable
issues that
that oneone must use
information.
information.
must consider these
consider Historical Historical
active
process. use data
Such are intended
active for to
applications be used
include to actively
using alter
theModels
models for
the
to
The
to effectively extract information and how we use these Historical
active use data
data
are isintended
is ideal
ideal for to
for building
building
be usedsuchtomodels.
such models.
actively Models
alter for
for
the
models
The
to focusto
Theeffectively
focus in aid flotation
in this
this paper is
paper
extract operation.
is on the
on the issues
information issuesandthathow
that one we
one mustuse
must consider
consider
these active
process.
optimize use
Such are
or are intended
active
control to
applications
the process be used
include
or to actively
using
to trouble-shoot alter
the models the
processto
to effectively
models extract
to aid flotation information and how we use these active
active
process. use
use
Such are intended
intended
active to
to
applications be
be used
used
include to
to actively
actively
using the alter
alter
models the
the
to
to
to effectively
effectively
models to aid extract operation.
extract
flotation information and
information
operation. and howhow we we use these process.
use these optimize
problems
process.
Such
or
or
Such gainactive
control applications
the
causal
active the process
information
applications
include
or to
from
include
using
the the For
trouble-shoot
data.
using the
models
process
the models
models
to
active
to
models
To to aid
analyse flotationdata,
historical operation.
one needs to make use of models, process.
optimize
optimize Such
or
or active
control
control applications
the process
process include
or
or to
to using
trouble-shoot
trouble-shoot process
processto
models
models
To analyse to
to aid
aid flotation
flotation
historical operation.
operation.
data, one needs todata makemining use ofor models, problems
use
optimize or gain
one needs
or control causal
causal information
models.
the process Causality
or from
to the data.
implies
trouble-shoot Forfor
that active
any
process
usually empirical, such as regression, latent optimize
problems
problems or control
gain
or gain the
causal process
information or to
from trouble-shoot
the data. For process
active
To
To analyse
analyse
usually
variable
historical
historical
empirical,
models. such
George
data,
data, one
one
asBox,
needs
needs
regression,
a famous
to make
todata
make use
use of
mining
statistics
models,
ofprofessor
models,
or latent active use onechanges
problems
problems
use one
needs
or
or gain
needs gain in causal
causal
causal
causal
causal
information
models.
the adjustable
information
information
models.
Causality
Causality
fromimplies
or manipulatable
from
the data.
the
the data.
fromimplies data.
Forfor
that
For
Forfor
that
active
variables any
in
active
active
any
To
To analyse
analyse
usually historical
historical
empirical, suchdata,
data, as one
one needs
needs
regression, to
to make
make
data use
use
mining of
of models,
models,
or latent use
activeone needs
changes causal
in the models.
adjustable Causality
or implies
manipulatable that for
variables any
in
usually
variable
used empirical,
models.
to empirical,
often say such
George
“Allas as regression,
Box,
models a famous data
are wrong mining
statistics
but some or latent
professor are active the
use
use process,
one needs
onechanges the
needs causal
inmodel
causalthe will
models. reliably
Causality
models. Causality
adjustable or predict the
implies changes
implies that
manipulatable that in
for
variables the
any
for anyin
usually
usually
variable empirical,
models. such
such
George as regression,
regression,
Box, a famous data
data mining
mining
statistics or
or latent
latent
professor active
the changes
process, the in the
model adjustable
will or
reliably manipulatable
predict the variables
changes in in
the
variable
used
useful”. models.
to The
oftenproblem George
say “Allis Box,
models
that a famous
most are
peoplewrong statistics
think professor
butof some
empirical are active output
active
the of interest
changes
changes
process, the in
in (MacGregor,
the
the
model adjustable
adjustable
will 2017).
or
or
reliably manipulatable
manipulatable
predict the variables
variables
changes in in
in
the
variable
variable
used to models.
models.
often George
George
say “All Box,
Box,
models a
a famous
famous
are wrong statistics
statistics
but professor
professor
some are the process,
output of the
interest model will
(MacGregor, reliably
2017). predict the changes in the
used
useful”.
models to often
The
as there say
problem “All
were is models
that most
interchangeable,are
peoplewrong think but
irrespective of some
empirical
of are
the the
the process,
process,
output of the
the
interest model
model will
will
(MacGregor, reliably
reliably
2017). predict
predict the
the changes
changes in
in the
the
used
used to
to often
often say
say “All
“All models
models are
are wrong
wrong but
but some
some are
are
empirical The output of interest (MacGregor, 2017).
useful”. The
useful”.
models
nature
The problem
as
problem is
thethere were
is that
that most
most people
is interchangeable,
people think think of
irrespective
of empirical
of thea The outputproblem
output of interest
of interest is (MacGregor,
that to guarantee
is (MacGregor, 2017).causality
2017).
in any set of
modelsofas
useful”.
useful”.
models
The
The
as data
problem
problem
there
there
or
were
were
theis objectives
that most of
that most
interchangeable,
interchangeable,
the problem.
people
people think of
think
irrespective
irrespective
ofWhether
empirical
empirical
of the
of the adjustable problem
The problem process
problem is
that
is that
to guarantee
variables
that to one
to guarantee needs
guarantee causality
causality
to have
causality in
in independent
any set of
in any
any setset ofof
nature
model
models of asthe
isas data or
useful
there werethe interchangeable,
depends objectives
upon threeof thefactors
problem.
irrespective Whether
(MacGregor,
of the theaa The adjustable process variables one needs to have independent
models
nature
nature of
of the
the there
data
data orwere
or the interchangeable,
objectives
the objectives of the irrespective
problem.
of thefactors
problem. of
Whether
Whether a The variation
The problem
problemin those
is that
is thatvariables,
to guarantee
to such
guarantee as would
causality
causality result
any from
in independent
in any set of
set ofa
model
2017):
nature is
of useful
the data ordepends
or upon
the objectives
objectives three
of the
thefactors
problem. (MacGregor,
Whether aa designed adjustable
adjustable process
process variables
variables one
one needs
needs to
to have
have independent
nature
model of
is the data
useful the
depends upon of
three problem. Whether
(MacGregor, variation
adjustable in those
experiment
process variables,
performed
variables onesuch on as
needsthe would
plant.
to have result
But
haveresult from
historical
independent a
model
2017): is useful depends upon three factors (MacGregor, adjustable variation
variation inprocess
in those
those variables
variables,
variables, onesuch
such needs
as
as to
would independent
from
from aa
model
model
2017): is
is useful
useful depends
depends upon
upon three
three factors
factors (MacGregor,
(MacGregor, designed
plant experiment
operating
variation in those data performed
almost
variables, never
such thewould
oncontains
as plant.
would suchresult
But historical
information,
result from
2017):
(i) The objectives of the model variation
designed
designed in those variables,
experiment
experiment performed
performed such on as
the
oncontains would
plant.
thecorrelated
plant. result
But
But from aa
historical
historical
2017):
2017):
(i) The objectives of the model plant
rather
designedoperating
mostexperiment data
variables almost
vary in
performed never
a highly
on the such
plant. information,
Butmanner and
historical
designed
plant experiment
plant operating
operating data performed
data almost
almost neveroncontainsthe plant. suchBut
such historical
information,
(i)
(i) The
The objectives
objectives of of the
the model
model rather
plant most variables
operating data vary innever
almost a highly
never
contains
containscorrelated
such
information,
manner and
information,
(i)
(i) The
The objectives
objectives of of the
the model
model plant operating
rather
rather most
most variables data almost
variables vary
vary in innever
aa highlycontains
highly such information,
correlated
correlated manner
manner and and
rather
rather most
most variables
variables vary vary in in aa highly
highly correlated
correlated manner
manner and and
Copyright 2018 IFAC
2405-8963 © 2018, 111 Hosting by Elsevier Ltd. All rights reserved.
IFAC (International Federation of Automatic Control)
Copyright
Peer review©under
2018 responsibility
IFAC 111Control.
of International Federation of Automatic
Copyright
Copyright © 2018
© 2018 IFAC
IFAC
10.1016/j.ifacol.2018.09.401 111
111
Copyright ©
Copyright © 2018
2018 IFAC
IFAC 111
111
IFAC MMM 2018
112
Shanghai, China, August 23-25, 2018 L. Bergh et al. / IFAC PapersOnLine 51-21 (2018) 111–116

the number of independent variations in the process is usually decisions affecting one flotation circuit will propagate to
much smaller than the number of process variables. This other circuits, and the disturbances created will come back
poses a major problem if we want causal models since most again to the feed by the recycling streams. Feedback control
of the data available in industry is historical operating data. of local objectives such as solid percent, froth depth, levels
Usually, this compromise the accuracy of model predictions, and flow rates have become essential part of any
however, thoughtful filtering of the data can aid to reduce this concentrator, however, two kind of problems are frequently
problem. presented. The first is how to choose the set points of these
local controllers in order to achieve global objectives. The
In this paper we present first the real problem to estimate second, is how to assure the quality of measurements on
model parameters from historical operating data and then which the local controls are based (Bergh et al., 2011).
how this kind of model may be used. In section 2 we discuss
the phenomenological approach and the information needed
to simulate the rougher circuit. In section 3 we present the
industrial plant layout and the kind of information available
together with the characterization of the feed to the plant. In
the next section we present the results of fitting the model
from industrial data, and finally we discuss how the model
can be used, giving some examples.

2. FLOTATION MODELING

2.1 Flotation Plant Description

The most simple flotation plant has at least the following

circuits: Rougher, Regrinding, Cleaner and Scavenger, as it is
shown in Figure 1 (Bergh and Yianatos, 2011). The output of
the grinding plant is fed to the Rougher circuit. The feed
coming to the Rougher circuit is separated in tailings and
concentrate. Usually pulp level control is available for each Fig. 1. Typical simplified flotation plant.
bank of the circuit. Air flow rates may be controlled or have
no regulation, depending on cell design. The rougher Phenomenological models, with parameters estimated from
concentrate is mixed with the scavenger concentrate and the sets of data collected in plant, can be used to aid flotation
mill output in a tank. The output of the tank is classified in a operation in different forms.
battery of hydro cyclones, where the overflow is the feed of
the cleaning circuit and the underflow is fed to the mill.
2.2 Phenomenological Approach
Usually the cleaner concentrate is the final product while the
cleaner tailings are the feed to the scavenger circuit. The
In this section we discuss the problem of building useful
cleaner circuit is generally composed by flotation columns
casual phenomenological models in the mineral processing
operating in parallel. Froth depth, wash water and air flow
area from historical operating data. Several researchers have
rates usually are under control. The scavenger tailings joint
been proposing conceptual models of the phenomena
the rougher tailings. Again, usually pulp level control for
involved. For example Finch and Dobby (1990) summarize
each bank is available and air flow rate control depends on
the phenomena occurring in flotation columns. Others, such
cell design. The overall control strategy of a flotation plant
as Bergh and Yianatos (2013) and Yianatos et al. (2012),
relies first on good control of local objectives (pulp levels,
have contributed to detailed modeling of rougher flotation
flow rates), usually as controllers implemented on a
circuits.
distributed control system (DCS). When these local
objectives are satisfactorily achieved, then the next level is to A common issue is that a large amount of input and output
be able to modify the operation of each circuit (Rougher, information is required. For example, in a rougher circuit the
Cleaners, and Scavenger) in order to obtain specific process feed is characterized by properties that are distributed
concentrate and tailing grades. This demands the capability of in nature. A particle size distribution means that every
changing the set points of the local controllers in such a particle is different from another, presenting different degree
manner that the operation of the circuit is corrected every of liberation of each mineralogical specie, and therefore will
time. have a different kinetics of collection and a different
behaviour in the froth according to its stability, depending
Flotation operation is a complex task mainly due to changes
also of air bubble size distribution, frother concentration,
over time of main feed characteristics. Usually changes in
solids content, etc. This problem is approach by selecting
mineralogy, particle size distribution, degree of liberation,
some classes like fine, intermediate and course particles, and
among others, require the appropriate operational decision to
assigning some average properties to reduce the
first stabilize the process and then to achieve concentrates
dimensionality and the complexity of the model. Some
with high economic value while the metal recovery is
laboratory test may be included in the global characterization,
maximized (Houdoin et al. 2001). Furthermore, operational

112
 IFAC MMM 2018
Shanghai, China, August 23-25, 2018 L. Bergh et al. / IFAC PapersOnLine 51-21 (2018) 111–116 113
such as kinetics curves from batch essays under some pseudo
standard conditions, and then scaled to plant conditions. The
typical information to fit a model from experimental data is
shown in Figure 2 (Bergh and Yianatos, 2011):
Cell volumen Adjusted mass
Operating conditions: froth balance per size
depths, air flow rates class
Solids input: tph, %, density
Bubble load, top of froth
Kinetics responses per size class Froth recovery,
Residence time distribution: E Collection recovery,
kinetics constant per
For feed, concentrate and tailings size class
Cu and Mo grades and solid mass
(%) per size class: fine,
intermediate and coarse Calibrated model
Fig. 2. Information needed to fit a phenomenological model.
Since the general procedure for developing and calibrating
the simulator, step by step, is described in detail in Bergh and
Yianatos, (2013), and is not repeated here.
The uncertainties of this representation may be questionable,
but at least it is a practical approach to the problem. The
trends using these models are close enough to the real
behaviour of the process and may be useful to achieve
different objectives.
In practice, there are two kind of problems: the estimation of
parameters must use a historical operating data and all the
required information is usually not available on-line in plants.
Therefore, the process of building a model must be adapted to
these constraints and one can expect larger prediction errors.
One advantage of phenomenological over empirical models is
that it is possible to estimate operational losses. The
deviations from the ideal operation, can be estimated and
therefore its economic losses over time. This is very
important because with this kind of information we can
estimate the economic impact and therefore the incentives to
innovate.
2.2 Industrial Historical Operating data
Historical operating data is usually limited to few on-line
measurements. The frequency of measurements are not
related to the frequency of change of the measured variable
over time. For example, a reliable information from a
chemical analysis is about a composite collected over one
operating shift. Even when more frequent measurements of
metal grades are usually available, the many source of errors
present make them not suitable to make decisions based on
them. Furthermore, particle size distribution is measured as
P80 (80% passing a given size). This means the separation
only into two size classes, gives undetermined description of
the particle size distribution of fines and course particles.
Even more, if you use an average of the shift to describe
particle size or a metal grade is meaningless unlike the
variation over the shift is characterized by small standard
113
deviations. The fact that the feed characteristics are
determined by a previous process produce highly correlated
input variables, that it is the worse condition to estimate
model parameters (Box et al., 1976; Beck and Arnold, 1979).
Since the data do not follow a given design, there are periods
where the operation may be considered as not normal. For
example, the froth depth along the circuit includes values
were the pulp overflew into the concentrate, producing low
grade concentrates. Some criterion should be added to filter
the data in order to be considered normal and useful for
parameter estimation, reducing the model prediction errors. A
general form of leading with this kind of problem is the use
of projection methods, such as principal component analysis
(PCA), to detect main outliers that contaminated the data
base.
3. INDUSTRIAL FLOTATION PLANT
The rougher flotation circuit consists of three parallel lines of
eight self-aerated mechanical cells of 257 m3 with an average
residence time of 28 min. Some typical characteristics of the
feed are: 3800 tph of solids, with 34 % of solids, a Cu grade
of 0.6 % and particles with a 23 % +65#. The typical
operating characteristics are: froth depth between 10 and 25
cm with an air superficial velocity of 1 cm/s in each cell. The
froth depth profile is generally different for each line, and the
profile pattern is not always consistent over time. There exist
7 areas were the mineral is extracted in the mine, each one
with different composition related to the chalcopyrite,
chalcocite and pyrite fractions.
3.1 Characteristics of Data Available in Plant
The following constraints are present when the historical
operating data, as an average of one shift, of twelve hours,
was used:
i) There are composite samples of the feed, the global
concentrate and each of the three line tailings. Solids %, Cu
and Fe grades were available from laboratory essays.
ii) There exist on-line Cu grade measurements of the feed and
concentrate, however, they are usually shifted from chemical
essays, and therefore they are not used in this study.
iii) From the on-line information, the shift average of tph of
solids and % +65# for the feed, and the froth depths in each
cell were available.
iv) From the area of extraction of the mine, an estimate of the
presence of chalcopyrite, chalcocite and pyrite were used.
The distribution of each specie into the two classes were
estimated by using a polynomial regression.
v) The average rougher circuit recovery was calculated from
the previous information, and was available in the historical
data.
vi) The maximum recovery for each specie was obtained
from historical data from kinetics test done previously to
characterize each zone of the mine.
IFAC MMM 2018
114
Shanghai, China, August 23-25, 2018 L. Bergh et al. / IFAC PapersOnLine 51-21 (2018) 111–116

3.2 Adaptation of Phenomenological Model to Data Table 1. Model predictions for a base case
Concentrate Model Planta Error [%]
According to the data available in the historical database,
some simplifying assumptions have to be made in order adapt Cu grade [%] 8.60 8.66 0.70
the original rougher simulator to the industrial conditions. Recovery [%] 83.78 83.89 0.13
The incomplete information in this case, as compared to the Residence time [min] 38.00 37.00 2.70
data required following Figure 2, lead to the following
Solids [%] 17.57 17.45 0.68
approach:
Solids mass rate [tph] 222.48 225.26 1.24
i) The valuable mineralogical species are carry into the froth
by true flotation. The gangue is carry into the froth by Cu grade recovery
entrainment. 6

Prediction error
ii) The mixing in each cell is represented by two tanks in 4
series, with a large time constant (0.9Ԏ) and a small time 2
constant (0.1Ԏ), where Ԏ is the cell residence time.
0
iii) The phenomenological model, adapted for two size
-2
classes: fine and coarse, has a total of 32 parameters. 23 of
them are related to the collection zone, 3 to the froth zone. 3 -4
to gangue recovery, 3 to water recovery and 2 to adjust the 1 2 3 4 5 6 7 8 9 10 11 12
selectivity in the froth. Selected shifts
iv) 15 parameters were assigned fixed values, according to
general information available. The 16 parameters associated Fig. 3. Prediction errors for a set of shifts using the first
to maximum recovery per class in each cell were reduced to 2 model obtained.
parameters by using a fixed trend of decreasing recovery
A second model was obtained with new parameters by
along the cells of the circuit.
minimizing the sum of squares of prediction errors, centred in
v) In the froth two parameters were used to modify the froth zero. The new model reduce the sum of squares from 127 to
recovery. One is related to the froth stability and other to the 99 in recovery predictions and from 46 to 45 in Cu grade
froth sensitivity between fine and coarse particles of valuable predictions. The new prediction errors are shown in Figure 4:
minerals.
Cu grade recovery
4. INDUSTRIAL ROUGHER FLOTATION MODEL 8
Prediction error

The industrial data were collected from the first of January to 6

the sixth of September of 2017. From them 437 shifts were
selected. Since there are seven mine areas with different
minerals contents, the data was classified according to the
mineral origin. In this work we present the results of just one
of them, corresponding to one type of run of mine. 78 shifts
were available, however, a filter of the data considering that
all froth depth in each cell were at least 10 cm, lead to a small
set of 29 shifts. A detailed information on the data base can
be found in Inostroza (2017).
To explore the parameter estimation methodology a set of
data corresponding to an average operation was selected. The
feed characteristics were: 3825 tph of solids, 34.1 % solids,
0.60 % Cu grade and 22.9 % +65#. The concentrate obtained
has a 8.66 % Cu with a 17.45 % solids. The Cu rougher
recovery was calculated to be 83.9 %.
After setting the model parameters the predictions are shown
in Table 1. These results show that the model is flexible
enough to predict the metallurgical results with small
prediction errors. However, looking for a general model to
represent the rougher circuit behaviour, we can see the
predictions errors when the previous model is used to 12
observations of the data base selected, in Figures 3. As one
can see prediction errors in recovery as well in Cu grade are
significant at least in half of the cases.
4
2
0
-2
-4
1 2 3 4 5 6 7 8 9 10 11 12
Selected shifts
Fig. 4. Prediction errors for a set of shifts using the second
model
One can see that both prediction errors decrease, in general,
with the exception of shift 5 and 10. One plausible
explanation is that the measurement values that contained the
historical database have considerable error. Another
explanation is that the operating choice especially of froth
depth profile is not symmetric for each of the three lines
and/or the profile itself may not be adequate. For example,
Figure 5 shows the froth depth for each cell in each line. One
can observe the lack of symmetry and the arbitrary pattern of
each profile. If these shifts are not considered, the prediction
errors are centred in -0.05 % and present a standard deviation
of 1.72 % for Cu grade and are centred in -1.17 % and

114
 IFAC MMM 2018
Shanghai, China, August 23-25, 2018
present a standard deviation of 1.73 % of for recovery. More
details can be found in Inostroza (2017).
60
Froth depth (cm)
40
20
0
1 2 3 4 5 6
cell number
Line 1 Line 2
Fig. 5. Froth depth profile for each line.
Similar results were observed for models developed for each
different mine location.
5. APPLICATION OF THE INDUSTRIAL MODEL
If one intend to reduce the prediction errors one must
examine very careful the impact of the uncertainties in the
measurement of each variable used in the model.
5.1 Sensitivity Analysis of the Industrial Model
As was mentioned before the flotation process is very
complex and historical operating data are imperfect. The aim
of building a reliable model, based on these data, with
accurate metallurgical predictions is, in practice, an
impossible task. The objective then is to have reliable models
useful to show the appropriate trends when a change in an
independent variable occurs. In this sense the use of such
models is intended to aid operators training, on-line decision
support for operation to analyse different possible scenarios
and also to be part of heuristic control strategies. One other
important issue is that these phenomenological models can be
used to estimate how the prediction errors depend on the
inaccuracy of some key measurements. In this section we
present some cases to illustrate this point.
5.1.1 Sensitivity Analysis to Uncertainties in Froth Depth
Forth depth is the most used manipulated variable to modify
the operation of a mechanical cell. However, since this
measurement is not standard, many sources of error
contribute, in general, to poor estimations. In practice, when
these on-line measurements are compared with others
manually made, errors usually exceed 20%. Then the
question is what will be the prediction error in grade and
recovery due only to this fact. Using the model based on the
industrial data for a typical operation, the following
deviations occurred, shown in Figure 6. In this case the
change in concentrate grade and recovery is due to a
decrement of the froth depth in all the cells. Contributions to
prediction errors for any other specific measurement error in
the cell array can be obtained.
One can see that common measurement errors as 20%
produce a prediction error of 1.6% in grade and 2.0% in
L. Bergh et al. / IFAC PapersOnLine 51-21 (2018) 111–116 115
recovery. Therefore, even if the model were perfect, you can
expect this magnitude in errors when using an imperfect data
base.
7 8
Line 3
Fig. 6. Increment of model prediction errors caused by error
in froth depth measurements.
5.1.2 Analysis of Operating Losses
A second issue is how to evaluate the operational losses due
to the use of inaccurate measurements in the decision making
system, in order to move the operation of the circuit to satisfy
metallurgical objectives, such as concentrate grade and
recovery. This idea is not developed in this specific work, but
certainly is of great economic impact and deserve more
discussion. For example, what is the economic impact of
using an inadequate maintenance plan for this
instrumentation?
5.1.3 Analysis of Froth Depth Profile
A third issue is the selection of one strategy to set the froth
depth profile along the circuit. If the data reflect the profiles
shown in Figure 5, with unjustified difference between lines
and without a clear pattern, this will be also another source to
increase the model prediction errors. A simulator based on
the model can be a valuable tool to examine different
scenarios. A subset of the industrial data was used to
illustrate this point. In general the froth depth profiles from
the data are similar to those illustrated in Figure 5, then for
the same feed characteristics three different profile patterns
were simulated: plane, ascending and descending. In order to
compare the results, each type of profile was set to achieve
the same Cu concentrate grade as the one observed originally
in the plant. Then the resultant recovery for each profile can
be compared. From the results shown in Figure 7, one can
observe that the best profile to increase recovery and
maintain the Cu grade is the descendent, then the ascendant
and then the plane. All profiles gave better performance than
the one obtained with the original plant profile.
6. CONCLUSIONS
The experience of adapting a phenomenological model to the
available information contained in a historical operating data
base is discussed.
115
IFAC MMM 2018
116
Shanghai, China, August 23-25, 2018 L. Bergh et al. / IFAC PapersOnLine 51-21 (2018) 111–116

Ingeniería Química, Departamento de Ingeniería

Química y Ambiental, Universidad Técnica Federico
Santa María.
Yianatos, J., Carrasco, C., Bergh, L., Vinnett, L. & Torres, C.
(2012) Modeling and simulation of rougher flotation
circuits. International Journal of Mineral Processing,
Volume 112-113, pp. 63-70.

Fig. 7. Increment in recovery due to the pattern chosen of

froth depth profile.
The major contribution is the development of a methodology
to adapt phenomenological models to the data available on-
line in an industrial plant, in spite of the limitations found in
practice. Several sources of errors can be present in this kind
of data base, producing large metallurgical prediction errors.
In spite of that, the model can be applied to improve on-line
operating decisions, testing new operating scenarios, and
being a valuable tool to train plant operators.
Finally, one important issue is that this kind of model can be
used to evaluate the economic impact of uncertainties in
measurements.
ACKNOWLEDGMENT
The authors thank the financial support of Conicyt, Fondecyt
Project 1160105, and the collaboration of Operación Los
Bronces, from AngloAmerican Chile, to permit access to
their industrial historical operating database.

REFERENCES
Beck J., Arnold K. (1977) Parameter Estimation in
Engineering & Science, John Wiley and Sons, New
York.
Bergh L.G., Yianatos, J.B. (2011). The long way toward
multivariate predictive control of flotation processes.
Journal of Process Control, 21, 226–234.
Bergh L. and Yianatos J. (2013) Control of rougher flotation
circuits aided by industrial simulator. Journal of Process
Control, 23, 140-147.
Box G.E.P., Hunter W.G., Hunter S.H. (1978) Statistics for
experimenters, John Wiley and Sons, New York.
Finch J., Dobby G. (1990) Column Flotation, Pergamon
Press, Oxford, England.
Hodouin D., Jämsä-Jounela S.-L., Carvalho M.T., Bergh L.,
(2001) State of the art and challenges in mineral
processing control. Control Engineering Practise, 9, 995–
1005.
MacGregor J.F. (2017) Empirical Models for Analyzing
“BIG” Data, retrieved from www.prosensus.ca in
october, 2017.
Inostroza K. (2017) Simulador de circuito rougher de
flotación de Planta N°2, Las Tórtolas, Operación Los
Bronces, AngloAmerican Chile, Tesis de magister en

116