From: Ruel C. Bato, Jr.

Date: May 27, 2022

Subject: Flotation Level Controller Fine Tuning

To: PROCESS PLANT MANAGER

I. Objective

• To utilize flotation cell automatic level controller and establish a slurry level that
optimizes pull-out of the desired material in the flotation cell by regulating the level
controller.

II. Method

Met Team lead by Ms. Batalla, performed the scheduled fine tuning of the flotation cell level
controller.

Listed below are the activities performed by the team.

1. Checked the control system of the flotation level controllers and asked permission
from our instrument team to adjust the current PID setting.
Listed on the table below are the PID values before and after tuning.
2. Adjusted the level set point of each cell to maximize pull-out while ensuring the
quality of the concentrate being claimed.
3. Slurry level set point was positioned to attain the smallest variation or movement of
the dart valve or process value.

ROUGHER PID Initial Value Current Value

P (Proportional) 100% 30%
I (Integral) 10,000 s 60 s
D (Derivative) 0 0.5

High Limit, in 24.00 24.00

Low Limit, in -1.00 1.00

SCAVENGER PID Initial Value Current Value

P (Proportional) 100% 30%
I (Integral) 10,000 s 60 s
D (Derivative) 0 0.5
 High Limit, in 24.00 24.00
Low Limit, in -1.00 1.00

CLEANER PID Initial Value Current Value

P (Proportional) 100% 50%
I (Integral) 10,000 s 60 s
D (Derivative) 0 0.5

High Limit, in 24.00 24.00

Low Limit, in -1.00 -1.00

Cell Current Set Point (SP), in

Rougher 3.7
Scavenger 10
Cleaner 12

III. Encountered Issues

• Very slow reaction time of the level controller. While the process value (PV) is far
from the set value (SV), the dart valve won’t even budge from its position.
• Abrupt changes of the flotation feed flow rate.

IV. Results and Discussion

• Dart valve reacts spontaneously with the Set Point (SP) after changing the PID of the
level controllers. Automatic level control system of the cell is now functional.

V. Recommendation

• Flotation operators to utilize the auto level control function of the rougher,
scavenger and cleaner cells.
• Continue fine tuning of the level controller to optimize the set point and improve
operators’ confidence with the system.
• Install an additional support on the auto dart valve to eliminate high vibration
during its up-down movement.