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Model Predictive Control

And Analytics For Mining

Lance Rodenfels
Rockwell Automation

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Agenda

Agenda

1 Intro

2 Leveraging Digital
Technologies for
Process
Optimization 3 Model Predictive
Control
4 Applying Model
Predictive Control
to Mining

5 6
MPC Platform Value Delivery
Considerations Approach

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Rockwell Automation

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Mineral Processing
Ore grades are declining and ores are becoming more complex

Process
characteristics Process objectives
Grade decline Reduce cost per ton

Variability in raw materials and Lower plant costs

supplies, as well as internal and
external disturbances Lower energy intensity

Critical variables difficult to Energy and water consumption

measure
Extend the life of existing ore
Complexities in operations and bodies
chain synchronism
Continue to meet regulatory
Long working stock in processing requirements
chain
Increase operator productivity

How to achieve process objectives in

such complex operations?

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Leveraging Digital
Technologies for Process
Optimization

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Basic Control Strategies

Aren’t Enough
Although regulatory control provides adequate control in terms
of plant safety, it rarely achieves optimal control in quality, nor
does it operate in the most economical fashion

The hardness, grade and rock size vary greatly

Frequent unmeasured disturbances
Variability by minute
The processes are complex, with many circulating loads More than 75% of mineral
Process Limit
processing plants
are still using basic
control strategies

Source: Grinding Mill Circuits - A Survey of Control and

Economic Concerns - Department of Electrical,
Electronic and Computer Engineering, University of
Pretoria

Traditional Regulatory Model

operation control predictive

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Machine Learning
Enables a system to learn from data

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Model Predictive Control

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How Model Predictive Control

Generates Benefits
Reduce variability, increase recovery and save consumables

104
REDUCES variability
102
Process/Specification Limit
100 ACHIEVES plant stability

98
MANAGES the process
96 within constraints
Benefits
94
Push process
toward limits ACHIEVES UPLIFT –
92 Variability under Variability reduction Maintain quality just operate closer to
operator control with MPC within specification
specifications and
Before During After performance limits while
TIME maintaining safety margins

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Model Predictive Control Solution:

From Model To Execution
Example of a fictitious flotation optimization

Data collection Model matrix Optimization / visualization

Concentration  Concentration 
Sump Level Recovery
Zn Pb

Process trends
Air

Level

Variation example
Collector

Feed Zn

Production rate
Feed Pb
example

It shows dynamic relationships between

process outputs and inputs Control utilization
example

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Model Predictive Control Solution

MPC is a proven technology that improves plant and asset

performance by reducing process variability

Controller based or software based

Hybrid modeling functionality allows the user to

take advantage of all known information
(empirical data, equations, equipment
specifications, etc.)

Handle slow or complex processing lags

Virtual Online Analyzers replace sparse, or

infrequent, feedback from lab or analyzer

Console for KPI’s, value presentation and

runtime visualization

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Applying Model Predictive

Control to Mining

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Grinding Application

Process challenges MPC delivers

Multiple interactions not Maximize throughput within

easily handled constraints

Relationship between Decrease energy per ton

feed, weight and speed is
variable and non-linear Increased stability

Still requires operator Finer product grind sizes or

intervention with extensive reduction in particle size
experience variation, primarily controlled
via the ball mill power (and
Sump pump causes water hence media addition)
balance/density
disturbance Extend wear life

Potential gains:
Up to 10% increased throughput and same on
reduced specific energy, with a P80 variability
reduction of up to 50%

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Flotation
Increase recovery and save consumables

Process challenges MPC delivers

Flotation is still a complex Increased rougher recovery

process and not fully
understood and remains Increased and stabilized
relatively inefficient cleaner grade

Traditionally more floor Optimized reagent

operator control consumption

Variable mineralogy,
throughput rates and ore
types

Potential gains:
Increased recovery of up to 3%, reduction of
reagents of up to 3%

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USE CASE

Model Predictive Control

Optimal control of iron ore flotation: iron ore mine

Pellet feed concentration

On average, 100 gr less amine was used
per feed SiO2 ton yielding significant
USD savings Before MPC After MPC
100%

80%

60%

40%

20%
Allowed the user to step up production
of the most valuable concentrate type from 0%
46% to 73% on average

%PF (% SiO2 >1.55)

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Thickeners
Improving flocculation and dewatering performance

Process challenges MPC delivers

Water conservation Increased underflow

density
Optimum reagents
consumption Decreased flocculent
consumption
Little control and local
knowledge Improved overflow clarity
Better water utilization
Not often integrated into
control system

Potential gains:
Increased water recovery of up to 3%, reduction of
flocculent of around 2%

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Material Flow Management

Route optimization: Maximizing material throughput

Process challenges MPC delivers

Inconsistent production Maximizing ore flow

rates
Operate to maximum
Loss of production at constraints
shift change
Minimize equipment trips
Conveyor system trips Extending equipment life

Minimize interruptions during

shift changes

Energy conservation and

maintaining the maximum
throughput

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MPC Platforms

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MPC Platforms

Scalable Model Predictive

Control (MPC)

• ControlLogix® module in the

chassis
• Server-based solutions; any Scalable products from
DCS integrated to hardware
• Small to medium sized
• Medium to large sized agnostic
• Linear processes (or
• Linear – nonlinear processes
adaptive systems)
• Complex process applications
• Fast process applications

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Value Delivery Approach

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Project Methodology

Assess Deliver Audit Sustain

• Propose & plan • Design, develop, deploy • Commissioning • Support
• Confirm business value • Data gathering and validation • KPI configuration • Knowledge transfer
• Set expectations • Model development • Training • Performance metrics
• Determine benchmark metrics • Application deployment • Performance validation • Ongoing support

VALUE-BASED PROPOSAL VALUE-BASED SOLUTION MEASURE VALUE ONGOING VALUE

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Thank you

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