Dynamic hybrid modeling and simulation of grinding–flotation circuits for the development of control strategies

Abstract

Process simulation is a very important tool for the design, development, analysis and optimization oftechnical processes in the mineral industry. The ability to simulate process behavior without the costof test runs can prevent the loss of man-hours and production, in addition to providing a platform forthe development of control tools and strategies. The usefulness of a simulator ultimately relies on howaccurately the underlying mathematical model represents real behavior. In mineral processing, due tovaried complexities such as strong non-linearities, variable coupling, time varying parameters, etc.; thedevelopment of accurate process models becomes an increasingly difficult task.This paper describes the modeling and simulation of the main components of a concentrator plant, thegrinding and flotation circuits. A hybrid dynamic model was favored to better represent the differentmodes of operation and non-linearities exhibited by the plant. Industrial plant data was used to calibratethe models used in the simulator. Simulation tests show that the performance of the simulator is qualitativelysimilar to that of a real plant, and it can be effectively used as a tool for the design and simulationof control solutions.