Chapter eight process control

8-1 Introduction

Gold plants are often operated with process control and optimization strategies that are
inadequate and poorly supported. In recent times, however, plants are increasingly gaining
substantial benefits by the installation and operation of good control systems that increase , save
costs and streamline operation. Typical benefits could be regarded as one or more of the
following[1]:

 A 15% reduction in the gold reporting to tailings;

 A 10% reduction in crusher power;

 A 20% reduction in reagent consumption;

 A 10% increase in plant throughput;

 Very few spillages and unscheduled shutdowns; and

 Improved productivity and working conditions for plant personnel.

A large portion of the benefits obtainable from process control can be obtained from good
basic control. Most of the infrastructure required for basic process control is standard and readily
available commercially[1].

In this chapter we define our control system for most of our equipments ,but before that we
will shed light on some conceptions like the element of the control system and the control block
diagram[1].

8-2 Element of control loop[2]:

The control loop consists of the following basic elements:

1) the measuring element.

2) the regulating elements(actuator).

3)the controller.

4)the process itself.

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8-3 Element of control loop in gold plants:

8-3-1 measuring element in gold plants:

Online measurements are key to a process control system. They warn the system of coming
input disturbances and they provide feedback on variables that should be stabilized, regulated
and optimized. Some of the most important variables measured on gold plants are as follows[1].

 Solids flow on a conveyor belt:

Nuclear meters and weightometers are standard and in common use for measuring solids flows
on conveyor belts. Weightometers are often more and give less ‘noisy’ signals. Nuclear meters
are non-mechanical and can be more reliable and less costly. The calibration of these meters is
typically done or checked by belt cuts, in conjunction with measurements of belt speeds. The
positioning of the meters on conveyor belts is important, because the delay while the solids are
on the belt can have an adverse impact on process control. The dynamics of feed belts can result
in poor controllability of the solids feed, and the need for advanced control methods for good
control[1].

 Slurry flow rate:

Magnetic-induction flow meters are the most common and reliable means of measuring the
flow of slurries. Calibration of these meters is often done by the physical measurement of water
flows where this is possible. Sometimes this calibration is done off-site[1].

 crusher power:

Crusher power is a good indication of the rate of crushing in a crusher. Measurements of

crusher power generally contain unusually large components of noise. Their use is therefore
often unnecessarily constrained to quite long term control strategies. Actually, advanced
electrical and digital processing of the signals from crusher power meters can eliminate
unwanted noise, leaving a fast-responding signal with good process information for control[1].
 Slurry levels:

Where there is little or no froth present, direct ultrasonic meters are often used reliably for
level measurements. Problems can arise beyond extremes of measurement ranges if the meter
gives unexpected outputs. Ultrasonic meters are also used quite commonly for flotation cells[1].

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 Grade:

Online measurements of gold concentrations in various process streams would be good to

have for control, but are generally not practicably possible for gold. This is especially true in
respect of solids in tailings streams, where the measurement of grade would be most useful[1].

 Cyanide concentration:

Titration and electrochemical methods have been applied with success to measure cyanide
concentrations in absorption and leaching vessels. They can give good indications of the leaching
strength of solutions that contain multiple cyanide complexes, because they tend to measure the
concentrations of those complexes that tend to be available for leaching gold[1].

8-3-2 Actuators in gold plants:

A control system influences the operation of a process by sending signals to actuators. The
number and types of actuators determine how many and
which variables on the plant can be controlled[1].

Although actuators are usually designed to act linearly, they often have
some undesirable characteristics or there might be some unfavorable dynamics in the way the
plant reacts to them. Where possible, good control
strategies therefore have a local fast-acting control loop for each actuator that regulates a
measurement of the associated plant input. In fact, inexpensive actuators with poor
characteristics can often be made to give very good results when a fast-acting local loop can
overcome its faults. This is particularly true of valves where there are associated measurements
of flow rates[1].

8-3-3 controllers in gold plants:

Proportional-integral (PI) feedback control loops are commonly used on gold plants. Because
of the noisy measurements generally present on these plants, derivative action tends to cause too
much actuator action and is rarely used[1].
Many PI controllers are poorly tuned and few people know or remember how to tune them
properly. A ‘fiddle and test’ method of tuning often results in too low a gain and relatively too
much integral action. This occurs because when a control loop appears to be too active, them
operator’s natural inclination is to turn things down. This is effective in respect of the gain

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setting, but not the reset setting, which gives more integral action the lower it is. The integral
action is generally not immediate-acting, so adverse effects are not seen immediately when it is
set too high and the gain is made correspondingly small[1].
PI control is not always very successful. Problems can occur when there are adverse dynamic
characteristics. A more advanced controller can handle them dynamics of long time lags
introduced by solids-feed belts more appropriately[1].
Multivariable interactions between plant inputs and outputs are often
more appropriately dealt with by advanced control[1].

8-3-4 The processes in the gold plants:

In the gold plants the process can be the jaw crusher, belts, screen...etc.

8-4 Block diagrams

A block diagram is a convenient and concise way for representing complicated control
systems. Any control system can be transulated into a block diagram which shows the general
arangment of thesystem . A block diagram consists of blocks, linkages and summing points[2].

The following diagram show the standard symbols of block diagram

u
KL

m
P
v
A r + e c
Gc Gv + Gp

Figure(8-1): standard symbols of block diagram

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Variable symbols:

V = set point or desired value.

r = reference input.

e = error or deviation signal.

P= controller or command out put signal.

m = manipulated variable.

u = load variable.

C = controlled variable.

b = feedback variable.

Transfer functions symbols:

A = input transfer function.

Gc= control function generator transfer function.

Gv = regulating unit transfer function .

Gp = process transfer function.

H = measurement feedback transfer function.

KL = load gain transfer function.

Now let us see the control system of our equipments.

8-5 Control of the jaw crusher

In the jaw crusher we must control it and to Prevent it from inefficiencies such as running
empty or being overfed with material.
So the elements of control loop of the crusher can be:

 The measuring element:

Crushers are harsh environments for sensors because of substantial vibration, high electrical
and acoustic noise levels, in addition to rapidly moving material. Installing ultrasonic level
measurement technology to control the feed on the crusher improves operational productivity.

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 The controller:

As we mentioned before the PI feed back controller is the best controller for the most
operation of the gold plant, the controller will give it`s order of stopping the motor of the belts in
the case of overload of jaw crusher or when the crusher has stopped for any reason, the controller
will give it`s order of turning on the motor of the belts in the case of empty crusher.

 The actuator:

Here the actuator that take the orders from the controller in the form of signals is the motor of
the conveyor belts which will stop the belt when there is overload in the crusher or if the crusher
stop ,the tracks that carry the ore will stop when the belts stop . Also if the crusher is empty the
controller will stop the motor of the conveyor belt.

 The process:

the jaw crusher itself and the conveyor belts are the process.

leakage
u1 N1

Mechanical
friction
u2 K1

Gv Gp

P c
v
A r + LC Motor of crusher+
belts belts
Input element
b
Level
indicator

Measuring element

Figure(8-2): block diagram of the control loop of the jaw crusher

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V = set point = the level of the ore.

P= controller or command output= the position of the key of the motor of the belts.

u = load variable= leakage+ mechanical friction.

C = controlled variable= the level of the ore in the crusher.

b = feedback variable.

A = input transfer function.

Table(8-1): summary of the controlling of the jaw crusher

Process Crushing
Controller Automatic PI controller
Controlled variable the level of the ore in the crusher
Measuring element Ultrasonic
Regulating element Motor of belts
Load variable leakage+ mechanical friction
Set point The level of ore

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8-6 control of the screen:

In the screen the important thing is the level of the ore in the screen which must be control to
avoid the flooding of the ore outside the screen and also to avoid the empty of the screen, the
control loop will be:

 The measuring element:

In the screen we also will use ultrasonic level measurement technology because it has
approximately the same nature of the jaw crusher of substantial vibration, high electrical and
acoustic noise levels, in addition to rapidly moving material.
 The controller:
the PI feed back controller is the best controller for the most operation of the gold plant because
of the noise measurements that represent in the plant.

 The actuator:

The actuator is the motor of the jaw crusher which will stop the jaw crusher when there is
flooding in the screen or turn the crusher on if the screen is operating low flow of ore.

 The process

The process is the screen and the jaw crusher itself .

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leakage
u1 N1

Mechanical
friction
u2 K1

Gp
Gv
P c
v r + LC Motor of crusher+
A
jaw crusher
screen
Input element
b
Level
indicator

Measuring element

Figure(8-3):block diagram of the control loop of the screen.

V = set point = the level of the ore.

P= controller or command output= the position of the key of the motor of the jaw crusher.

u = load variable= leakage+ mechanical friction.

C = controlled variable= the level of the ore in the screen.

b = feedback variable.

A = input transfer function.

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Table(8-2): summary of the controlling of the screen

Process The screen

Controller Automatic PI controller
Controlled variable the level of the ore in the screen
Measuring element Ultrasonic
Regulating element Motor of jaw crusher
Load variable leakage+ mechanical friction
Set point the level of the ore

8-7 Control of the agglomeration drum :

Before the entering of the ore to the agglomeration drum there are two things that need
controlling:

a- The addition of cement.

b- The flow and the concentration of cyanide solution.

a- The addition of cement:

before the entering of the ore to the agglomeration drum there is addition of cement with flow of
8 kg for any ton of ore so it`s flow will be 1200 kg/hr which is need control in order to avoid the
excess flow of cement or the low flow of cement, and the control loop for this control will be:

 The measuring element:

The nuclear meter is suitable here for measuring the flow of ore because it is not expensive
and gives an accurate reads .
 The controller:

The PI feed back controller is used also here which is open and close the opining of the feeder
of cement to control the flow rate of cement.

 The Actuator:

The actuator is the bottom open of the feeder which will close if the flow rate of the cement is
greater than 1200kg/hr and will open if the flow rate is less than 1200kg/hr.

 The process is the conveyor belt .

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leakage
u1 N1
Vibration in
flow through
the feeder open
u2 K1

Mechanical
friction
u3 K2

Gp
Gv
P c
v
A r + controller Opening of
conveyor
belt
the feeder
Input element
b
nuclear
meter
Measuring element

Figure(8-4):block diagram of the control loop of the cement flow rate.

V = set point = the flow rate of cement which is equal 1200kg/hr .

P= controller or command output.

u = load variable= leakage+ mechanical friction+ Vibration in flow through the feeder open.

C = controlled variable= the flow rate of cement.

b = feedback variable.

A = input transfer function.

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Controlling cyanide solution flow and concentration before the agglomeration drum

Table(8-5): summary of the addition of cement before the agglomeration drum

Process The belt

Controller Automatic PI controller
Controlled variable the flow rate of cement
Measuring element Nuclear meter
Regulating element Opening of the feeder
Load variable leakage+ mechanical friction+ Vibration in
flow through the feeder open.

Set point 8 kg of cement

First the controlling of the flow of the cyanide solution

We must add the the cyanide solution with a flow rate of 0.000056m3/sec so we must keep the
flow of cyanide solution with this flow ,the controlling loop of it will be:

 The measuring element:

The magnetic-induction flow meters are the most common and reliable means of measuring the
flow of sullries so we will use it here for measuring the flow rate of the cyanide solution.
 The controller:

the PI feed back controller is used here in order to demining if the controlling valve will open or
close according to the measure flow through the magnetic –induction flow meter, if the flow rate
of the cyanide solution is greater than 0.000056m3/sec the controller will give it`s order to close
the valve and if the flow rate is less than 0.000056m3/sec the controller will open the valve .

 The Actuator:

Here we need a valve after the feeder of the sodium cyanide which will open or close according
to the order that it will have from the controller .

 The process is the pipes that carry the cyanide solution.

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leakage
u1 N1

solution
temperature
u2 N2

Solution
viscosity
u3 N3

Pipe
characteristic
u4 s N4

Valve
characteristics
u5 N5

Gv Gp
P
c
v
A r + valve pipe
controller

Input element
b
Flow indicator

Measuring element

Figure(8-5):block diagram of the control loop of the flow rate of cyanide soultion before the
agglomeration drum.

V = set point = the flow rate of cyanide solution which is equal to 0.000056m3/hr.P= controller
or command output.

u = load variable= leakage+ solution temperature+ solution viscosity+ valve characteristics +

pipe characteristics.

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C = controlled variable= the flow rate of cyanide solution.

b = feedback variable.

A = input transfer function.

Table(8-4): summary of the controlling of the flow rate of cyanide before the agglomeration
drum

Process The belt

Controller Automatic PI controller
Controlled variable the flow rate of cyanide solution
Measuring element Magnetic induction
Regulating element Valve
Load variable leakage+ solution temperature+ solution
viscosity+ valve characteristics + pipe
characteristics.

Set point 0.000056m3/hr

Second :the controlling of the concentration of the cyanide solution

We must add the the cyanide solution with a concentration of 1.2 x 10-3 kg/lit so we must keep
the concentration of cyanide solution with this level ,the controlling loop of it will be:

 The measuring element:

Electrochemical indicator is used here to measure the concentration of cyanide solution

because it give good indications of the concentration of the cyanide solution.

 The controller:

The PI feed back controller control the concentration of the cyanide solution by open and
close the feeder of sodium cyanide in the second calibration pond.

 The Actuator:

the actuator is the bottom open of the feeder which will close if the concentration of the sodium
cyanide is greater than 1.2 x 10-3 kg/lit and will open if the concentration is less than 1.2 x 10-3
kg/lit.

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 The process is the second pond that used for the calibrate the sodium cyanide .

Impurities in
NaCN
u1 N1

Mechanical
losses
u2 N2

Gv Gp
P
v r + c
A Bottom pond
controller
open of the
feeder
Input element
b
Concentration
indicator

Measuring element

Figure(8-6):block diagram of the control loop of the concentration of the cyanide solution that
feed before the agglomeration drum.

V = set point

= the concentration of the cyanide solution which is equal to 1.2 x 10-3 kg/lit.

P= controller or command output.

u = load variable= impurities in NaCN that feed to the pond +the mechanical losses.

C = controlled variable= the concentration of cyanide solution.

b = feedback variable.

A = input transfer function.

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Table(8-5): summary of the controlling of the concentration of the cyanide solution before the
agglomeration drum

Process The belt

Controller Automatic PI controller
Controlled variable the concentration of cyanide solution.
Measuring element Electro-chemical indication
Regulating element Bottom open of the feeder
Load variable impurities in NaCN that feed to the pond +the
mechanical losses.

Set point 1.2 x 10-3 kg/lit.

The controlling of the agglomeration drum

In the the agglomeration we just need to control the flow rate of ore for it which must be 150
ton/hr, so the control loop will be:

 The measuring element:

As we knew that the nuclear meter is suitable for measuring the flow of ore because it is not
expensive and gives an accurate reads .

 The controller:

As we mentioned before the PI feed back controller is the best controller for the most
operation of the gold plant, the controller will give it`s order of stopping the motor of the screen
in the case of overload of the agglomeration drum or when the agglomeration drum has stopped
for any reason, the controller will give it`s order of turning on the motor of the screen in the case
of empty drum.

 The actuator:

the actuator is the motor of the screen which will stop the screen when there is over load in the
agglomeration drum or turn the screen on if the drum is operating with low flow of ore.

 The process is the agglomeration drum itself.

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leakage
u1 N1
Vibration in
flow through
the feed open
u2 K1

Gp
Gv
P c
v
A r + controller Motor of
Agglomera
-tion drum
screen
Input element
b
Flow
indicator
Measuring element

Figure(8-7):block diagram of the control loop of the cement flow rate.

V = set point = the flow rate of ore which is equal to150 ton/hr .

P= controller or command output.

u = load variable= leakage+ vibration of flow through feed opening of the agglomeration drum.

C = controlled variable= the flow rate of ore.

b = feedback variable.

A = input transfer function.

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Table(8-6): summary of the controlling of the agglomeration drum

Process The agglomeration drum

Controller Automatic PI controller
Controlled variable the flow rate of ore
Measuring element Nuclear meter
Regulating element The motor of the screen
Load variable leakage+ vibration of flow through feed
opening of the agglomeration drum
Set point 150n/hr

8-8 Control of the heap

In the heap the we only need to control the flow and the concentration of cyanide solution

First the controlling of the flow of the cyanide solution

We must add the the cyanide solution with a flow rate of 0.02 m3/sec before the destribution of
it in the small pipes of drain so we must keep the flow of cyanide solution with this range ,the
controlling loop of it will be:

 The measuring element:

The nuclear meter is suitable here for measuring the flow of ore because it is not expensive and
gives an accurate reads

 The controller:

The PI feed back controller is used here in order to demining if the controlling valve will open
or close according to the measure flow through the magnetic –induction flow meter, if the flow
rate of the cyanide solution is greater than 0.02 m3/sec the controller will give it`s order to close
the valve and if the flow rate is less than 0.02 m3/sec the controller will open the valve .

 The actuator:

Here we need a valve after the feeder of the sodium cyanide which will open or close according
to the order that it will have from the controller .

 The process is the pipes that carry the cyanide solution.

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leakage
u1 N1

solution temperature

u2 N2

Solution
viscosity
u3 N3

Pipe
characteristic
u4 s N4

Valve
characteristics
u5 N5

Gv Gp
P c
v
A r + valve pipe
controller

Input element
b
Flow
indicator

Measuring element

Figure(8-8):block diagram of the control loop of the flow rate of cyanide soultion before that
feed to the heap.

V = set point = the flow rate of cyanide solution which is equal to 0.02 m3/sec.

P= controller or command output.

u = load variable= leakage+ solution temperature+ solution viscosity+ valve characteristics +

pipe characteristics.

C = controlled variable= the flow rate of cyanide solution.

b = feedback variable.

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A = input transfer function.

Table(8-7): summary of the controlling of the flow rate of cyanide that added to the heap

Process Pipes
Controller Automatic PI controller
Controlled variable the flow rate of cyanide solution
Measuring element Magnetic induction
Regulating element Valve
Load variable leakage+ solution temperature+ solution
viscosity+ valve characteristics + pipe
characteristics.

Set point 0.02 m3/sec

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Second :the controlling of the concentration of the cyanide solution

We must add the the cyanide solution to the heap with a concentration of 0.25 × 10-3 kg /Lit
so we must keep the concentration of cyanide solution with this level ,the controlling loop of it
will be:

 The measuring element:

Electrochemical indicator is used.

 The controller:

The PI feed back controller control the concentration of the cyanide solution by open and
close the feeder of sodium cyanide in the first calibration pond

 The actuator:

The actuator is the bottom open of the feeder (feeder of sodium cyanide which is above the
first pond of calibration ) which will close if the concentration of the sodium cyanide is greater
than 0.25 x 10-3 kg /lit
and will open if the concentration is less than 0.25 × 10-3 kg /lit.

 The process is the pipes that carry the cyanide solution.

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Impuities in
NaCN
u1 N1
Mechanical
losses
u2 N2

Gv Gp
P
v r + c
A Bottom pond
controller
open of the
feeder
Input element
b
Concentration
indicator

Measuring element

Figure(8-9):block diagram of the control loop of the concentration of the cyanide solution that
feed to the heap.

V = set point = the concentration of the cyanide solution which is equal to 0.25 × 10-3 kg /lit

P= controller or command output.

u = load variable= impurities in NaCN that feed to the pond +the mechanical losses.

C = controlled variable= the concentration of cyanide solution.

b = feedback variable.

A = input transfer function.

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Table(8-8): summary of the controlling of the concentration of the cyanide solution that added
to the heap.

Process The pond

Controller Automatic PI controller
Controlled variable the concentration of cyanide solution.
Measuring element Electro-chemical indication
Regulating element Bottom open of the feeder
Load variable impurities in NaCN that feed to the pond +the
mechanical losses.

Set point 0.25 x 10-3 kg /lit

8-9 The control of the Leaf- pressure filter :

Here we must control the pressure of the pregnant solution to the leaf-press filter to keep it at 7
bar ,so the controlling loop of it will be:

 The measuring element:

The pressure indicator is used.

 The controller:

The PI feed back controller is used here and it gives it`s order to the valve

 The actuator:

Here we need a valve after the the storage pond and before the leaf-pressure filter which will
open or close according to the order that it will have from the controller .

 The process is the pipes that carry the pregnant solution

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leakage
u1 N1

solution temperature

u2 N2

Solution
viscosity
u3 N3

Pipe
characteristic
u4 s N4
Valve
characteristics
u5 N5

Gv Gp
P c
v
A r + valve pipe
PC

Input element
b
Pressure
indicator

Measuring element

Figure(8-10):block diagram of the control loop of the flow rate of the pregnant solution to the
leaf filter.

V = set point = the pressure of pregnant solution which is equal to 7bar.

P= controller or command output.

u = load variable= leakage+ solution temperature+ solution viscosity+ valve characteristics +

pipe characteristics.

C = controlled variable= the flow rate of pregnant solution.

b = feedback variable.

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A = input transfer function.

Table(8-9): summary of the controlling of the flow rate to the leaf- pressure filter

Process The pipes

Controller Automatic PI controller
Controlled variable the flow rate of pregnant solution
Measuring element Magnetic induction
Regulating element Valve
Load variable leakage+ solution temperature+ solution
viscosity+ valve characteristics + pipe
characteristics
Set point 7 bar

8-10 The control of the de-aeration tower:

In the de-aeration tower we must keep the flow rate of the pregnant solution to the tower with
73.8m3/hr and the flow rate of the air to the bottom of the de-aeration tower with 0.00829kg/hr.

The controlling loop for the flow rate of the pregnant solution to the de-aeration tower will
be

 The measuring element:

The nuclear meter is suitable here for measuring the flow of ore because it is not expensive
and gives an accurate reads.

 The controller:

The PI feed back controller is used here in order to demining if the controlling valve will open
or close according to the measure flow through the magnetic –induction flow meter, if the flow
rate of the cyanide solution is greater than 73.8m3/hr the controller will give it`s order to close
the valve and if the flow rate is less than 73.8m3/hr the controller will open the valve .

 The actuator:

The actuator is a valve before the de-aeration tower which will open or close according to the
order that it will have from the controller.

 The process is the top of the de-aeration tower.

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 Chapter eight process control

leakage
u1 N1

solution temperature

u2 N2

Solution
viscosity
u3 N3

Pipe
characteristic
u4 s N4
Valve
characteristics
u5 N5

Gv Gp
P c
v
A r + valve pipe
PC

Input element
b
Flow
indicator

Measuring element

Figure(8-11):block diagram of the control loop of the flow rate of pregnant solution to the de-
aeration tower.

V = set point = the flow rate of pregnant solution which is equal to 73.8m3/hr.

P= controller or command output.

u = load variable= leakage+ solution temperature+ solution viscosity+ valve characteristics +

pipe characteristics.

C = controlled variable= the flow rate of pregnant solution.

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b = feedback variable.

A = input transfer function.

Table(8-10): summary of the controlling of the flow rate of the pregnant solution to the de -
aeration tower.

Process The pipes

Controller Automatic PI controller
Controlled variable the flow rate of pregnant solution
Measuring element Magnatic induction
Regulating element Valve
Load variable leakage+ solution temperature+ solution
viscosity+ valve characteristics + pipe
characteristics
Set point 73.8m3/hr

The controlling loop for the flow rate of the air to the de-aeration tower will be :

 The measuring element:

A mass air flow sensor( vane meter sensor VAF) is used to measure the flow rate of air.
 The controller:

The PI feed back controller is used.

 The actuator:

The actuator will be the fan which at the end of the tower which entering the air from the
bottom of the tower,the fan turn on or shut down according to the order that it have from the
controller .

 The process is the bottom of the de-aeration tower.

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 Chapter eight process control

leakage
u1 N1

Air
temperature
u2 N2

Gv Gp
P
v
A r + vane Bottom c
controller of tower

Input element
b
Mass air flow
sensor(VAF)

Measuring element

Figure(8-12):block diagram of the control loop of the flow rate of air to the bottom of the de-
aeration tower.

V = set point = the mass flow rate of air=0.00829kg/hr.

u = load variable= leakage + air temperature.

C = controlled variable= the flow rate of air.

b = feedback variable.

A = input transfer function.

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Table(8-11): summary of the controlling of the flow rate of the air to the de -aeration tower.

Process The bottom of the de-aeration tower

Controller Automatic PI controller
Controlled variable the flow rate of the air
Measuring element Mass air flow sensor
Regulating element Fan
Load variable leakage+ solution temperature+ solution
viscosity+ valve characteristics + pipe
characteristics
Set point 0.00829kg/hr

8-11 The control of the filter-press:

In the press- filter we need to adjust the flow rate of the pregnant solution to the filter and this
can be done automatically by adjusting the level of solution in the mixer of zinc ,the level of the
solution in the mixer can be controlled by positioning a storage tank above it.

The top tank

float

Pipe
throat The mixer

Figure(8-13):the automatic control of the solution level in mixer.

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As shown in figure(8-13) when the solution come out in the pipe from the mixer the level of
solution in mixer decreases allowing the float to move down, this open the pipe throat at the
bottom of the tank, thus the solution flows into the mixer raising its level until it reaches its
desired value.

The control loop :

 The measuring element: bottom side of the float

 The controller: the float
 The actuator: Upper side of the float
 The process is the mixer.

leakage
u1 K1
Solution properties
variation
u2 K2

Variations in flow through

orifice
u3 K3

Gp
Gc Gv
c
v r + P The mixer
A The float Upper side
of float
Input element
b
Bottom side
of the float

Measuring element

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Figure(8-14):block diagram of the control loop of the mixer.

V = set point = the level of the solution.

P= controller or command output.

u = load variable= leakage+ variations in flow through orifice+ solution properties variations.

C = controlled variable= the level of solution.

b = feedback variable.

A = input transfer function.

Table(8-12): summary of the controlling of the flow rate of the solution to the mixer

Process The mixer

Controller Automatic PI controller
Controlled variable the flow rate of the solution
Measuring element Bottom side of the float
Regulating element Upper side of the float
Load variable leakage+ variations in flow through orifice+
solution properties variations.
Set point The height of the mixer

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8-12 The control of the furnace

As we know there is high temperature inside the furnace and this may causing pressure build-
up due to the steam accumulation , and because of that we must keep the temperature of the
furnace with1200oC to avoid the risk of furnace explosion, we can keep the temperature of the
furnace with the range by the cooling water that cooling the furnace from the outside through a
valve that let the cooling water enter in the case of high temperature inside the furnace

The control loop:

 The measuring element:

Temperature indicator is used to measure the temperature inside the furnace.

 The controller:

The PI feed back controller is used, the controller open and close the valve of the cooling
water according to the temperature inside the furnace.

 The actuator:

The actuator will is the valve of the cooling water which open and close according to the
order that it receive from the controller .

 The process is the furnace itself.

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 Chapter eight process control

leakage
u1 N1

Valve
characteristics
u2 N2

Gv Gp
P
v
A r + valve furnace
c
TC

Input element
b
Temperature
indicator

Measuring element

Figure(8-15):block diagram of the control loop of the furnace.

V = set point = the temperature of the furnace which is 1200oC.

u = load variable= leakage + valve characteristics .

C = controlled variable= the temperature of the furnace.

b = feedback variable.

A = input transfer function.

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Table(8-13): summary of the controlling of the temperature in the furnace

Process The furnace

Controller Automatic PI controller
Controlled variable the temperature of the furnace
Measuring element Temperature indicator
Regulating element Valve
Load variable leakage + valve characteristics
Set point 1200oC

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8-13 References:

[1] M.Dadams, B.A.Wills ,"Development in mineral processing

volume15, Advances in gold ore processing", first edition,2005, Elsevier B.V
[2] M.E.Abu-Goukh, "Process dynamic and control 1" , first edition, 1994, G town.

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