EP0918566A1 - Procede et appareil de commande de machines de flottation - Google Patents

Procede et appareil de commande de machines de flottation

Info

Publication number
EP0918566A1
EP0918566A1 EP97925729A EP97925729A EP0918566A1 EP 0918566 A1 EP0918566 A1 EP 0918566A1 EP 97925729 A EP97925729 A EP 97925729A EP 97925729 A EP97925729 A EP 97925729A EP 0918566 A1 EP0918566 A1 EP 0918566A1
Authority
EP
European Patent Office
Prior art keywords
froth
flotation machine
sensor
control
analysis
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP97925729A
Other languages
German (de)
English (en)
Inventor
Michael G. Nelson
Kenneth S. Gritton
Lynn B. Hales
Donald G. Foot, Jr.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Baker Hughes Holdings LLC
Original Assignee
Baker Hughes Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Baker Hughes Inc filed Critical Baker Hughes Inc
Publication of EP0918566A1 publication Critical patent/EP0918566A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03D—FLOTATION; DIFFERENTIAL SEDIMENTATION
    • B03D1/00—Flotation
    • B03D1/02—Froth-flotation processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
    • B03B13/00—Control arrangements specially adapted for wet-separating apparatus or for dressing plant, using physical effects
    • B03B13/02—Control arrangements specially adapted for wet-separating apparatus or for dressing plant, using physical effects using optical effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03D—FLOTATION; DIFFERENTIAL SEDIMENTATION
    • B03D1/00—Flotation
    • B03D1/02—Froth-flotation processes
    • B03D1/028—Control and monitoring of flotation processes; computer models therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03D—FLOTATION; DIFFERENTIAL SEDIMENTATION
    • B03D1/00—Flotation
    • B03D1/14—Flotation machines

Definitions

  • This invention relates generally to froth flotation machines for the separation of particles from a liquid slurry or pulp More particularly, this invention relates to methods and apparatus for automatically monitoring, operating, and controlling continuous feed flotation machines using "intelligent" computer control systems and remote sensing devices, particularly laser spectroscopy type sensing devices
  • Flotation machines are used in many industrial applications for separation of particulate materials from suspensions in a liquid, usually water
  • a liquid usually water
  • the particles to be removed from the suspension are treated with reagents to render them hydrophobic or water repellant, and a gas, usually air, is admitted to the suspension in the form of small bubbles
  • the hydrophobic particles come into contact with the bubbles and adhere to them, rising with them to the surface of the liquid to form a froth
  • the froth containing the floated particles is then removed as the concentrate or product, while any hydrophilic particles are left behind in the liquid phase and pass out as the tailings
  • Flotation machines find particular utility in the metals recovery industry, providing superior recovery of metals or metallic minerals from a solid/liquid mixture known as a "pulp,” “slurry,” or “gangue "
  • the flotation process can also be applied to the removal of oil droplets or emulsified oil particles, as well as to fibrous or vegetable matter such as paper fibers, bacterial cells, and
  • reagents known as collectors selectively render one or more of the species of suspended particles hydrophobic, thereby assisting the process of collision with and collection by the air bubbles It is also usual to add frothing agents to assist in the formation of a stable froth on the surface of the liquid
  • conditioning is also usual.
  • the flotation machine includes a receptacle, a cell or tank with substantially vertical walls, and an inner rotating member known as a rotor-disperser
  • the rotor provides agitation to maintain suspension of the pulps, and may also draw external air into the tank through a standpipe
  • the disperser breaks the air into minute bubbles and disperses it uniformly through the pulp, while also providing mechanical mixing of the air and pulp
  • Such cells may also include a false bottom and a draft tube to provide a channelized flow path, ensu ⁇ ng maximum slurry recirculation and air/slurry mixing
  • the rotor functions only for agitation, and aeration is provided by an external means, usually a blower or compressor Alternatively, air may be dissolved into a liquid, which is then injected into the pulp or slurry
  • the air used may be atmospheric air, or an inert gas such as nitrogen or argon
  • Other proposed flotation cells may be atmospheric air, or an inert gas such as nitrogen or
  • a flotation machine is the column In a column, the conditioned suspension is introduced toward the top of the receptacle, a tall vertical column, and air bubbles are formed in the bottom of the column by blowing pressurized air through a diffuser A layer of froth bea ⁇ ng the floatable particles forms above the liquid and overflows from the top of the column The position of the froth-liquid interface is maintained at a desired level by controlling, for example, the flow of liquid from the bottom of the column
  • wash water is introduced near the top of the froth layer to create a downflow of liquid which tends to reduce the entrainment of undesired gangue particles in the froth overflow
  • the liquid flows downward while the bubbles rise vertically upward Since the rise of bubbles is related strongly to their size, the bubbles must be above a certain critical diameter to rise through the liquid and into the froth layer
  • Various other alternative embodiments of the column flotation machine have been desc ⁇ bed, for example in U
  • Flotation machines present challenging problems with respect to the design and installation of sensors associated with the flotation machines, the acquisition of various measurements, the ability to communicate data and power into and out of the flotation machine, as well as the ability to provide control devices within the machine and actuate those control devices in response to a command from a central control computer
  • a special challenge has been to improve efficient control of the various above-discussed parameters
  • Each of these parameters must be adjusted to optimize both the economic operation of the plant, as well the operating conditions, I e , efficient throughput and desired levels of pu ⁇ fi cation
  • Flotation machines are normally controlled by simple, feedback or feed forward control loops
  • Various devices have been described which may be used to monitor important parameters in flotation machine operation
  • the most common of these desc ⁇ be a flotation machine separation control system comprising a controller (e g , a microprocessor) which communicates with one or more sensors and in response to information received from the sensors, actuates a control apparatus (e g , a valve) to adjust one
  • U S Patent No 4,343,654 to Lambert uses feed forward and feedback control methods to detect solids concentrations and adjust the rate of chemical addition to feed streams
  • the control system includes optoelect ⁇ c detectors responsive to different solids concentrations and slurry parameters The detectors forward signals regarding the solids concentrations and slurry parameters to a process controller In response, the process controller adjusts the rate of addition of chemicals to the feed stream of the froth machine to control the separation of solids from impurities
  • the controller calculates a feed forward output from the signals and the controller output adjusts the addition of different chemicals or additives to the processing machine
  • the controller also calculates a feedback output after receiving a signal from a third detector which monitors
  • Ortner and Pfalzer A probe measures the level or amount of foam, and transmits a signal to a controller or regulating apparatus, which in turn controls the amount of air introduced into the system by way of a valve Control of multiple parameters is achieved in U S Patent No 3,551897 to Cooper, which describes measurement of various operating conditions, then calculation of a plurality of coefficients that together with certain equations describe the process at a particular point in time, and then utilization of the same equations to adjust certain parameters in order to optimize operating conditions and maximize profitability
  • control systems of the prior art address only one or two process or operational parameters, for example controlling the level of liquid or froth
  • U S Patent No 5,073,253 to Bishop and Gray a float supported by the froth works in tandem with an ultrasonic level detector to provide a measurement of froth level
  • U S Patent No 4,938,865 to Jameson utilizes a controller to operate a valve that introduces air into the top of a column
  • US Patent No 4,552,651 to Sandbrook and Scandrol discloses devices to measure pulp density and pulp level The two signals are then combined to a single signal which is utilized to control liquid level in the machine by adjusting the rate of withdrawal of tailings
  • U S Patent No 5,192,423 to Duczmal and Schneider use a control device to maintain the desired liquid level and to optimize the collection of froth
  • U S Patent No 5,368,166 to Chumak, et al discloses a control device to measure the level and density of pulp and to control the flow rate of water and frothing agent A differential densitometer for continuously measunng total undissolved solids in a liquid in U S Patient No 5,417,102 to Prevost
  • the rate of addition of chemical reagents for conditioning is one of the more important process parameters to control This rate affects both the quality of the product (i e , the amount of mineral extracted and the purity), as well as the cost of the overall process
  • U S Patent No 4,810,371 to Fonesca discloses a system to control the coal content of coal tailings, including detecting the coal content of the tailings from the flotation cell and controlling the supply of additives to the machine to optimize slurry coal recovery
  • a method and apparatus for sensing variations in solids content in at least one output stream and then adjusting the amount of flotation reagent is described in U S Patent No 4,731,176 to Macdonald
  • a particle size analyzer is used in U S Patent No 4,559,134 to compare a size analysis of solid particles in a separated stream with a size analysis of solid particles in a feed stream
  • the rate of addition of collector reagent is adjusted in response by a controller
  • An intelligent flotation machine of the type herein disclosed has the capability of sensing information about itself, predicting its own future state, adapting and changing over time as process and operational conditions change, knowing about its own performance, and changing its mode of operation to improve performance.
  • the control system of the present invention regularly receives instrument readings, digitized video images, or other data indicating the state of the flotation machine; analyzes these readings in terms of one or more self-generated, continuously updated, internal models; and makes changes in operating variables as suggested by the internal models.
  • a computer control system actuates at least one of a plurality of control devices based in part on input from one or more monitoring sensors so as to provide real time continuous operational control.
  • the sensor or sensors comprise a means for determining input stream composition and particle size.
  • a preferred sensor includes sensors utilizing laser spectroscopy (e.g., laser-induced breakdown and laser-induced mass spectroscopy).
  • laser spectroscopy e.g., laser-induced breakdown and laser-induced mass spectroscopy
  • Such sensors may oscillate in an arcwise path, or move linearly along the process flow or radius of the tank to provide a profile of the process stream without the necessity of removing individuals samples from the process stream.
  • multiple, spaced sensors may be used to obtain a complete process stream profile.
  • a particularly preferred embodiment of the present invention employs an imaging system comprising video cameras producing images which are converted to data usable by the process models of the present invention.
  • This embodiment will further comprise an advanced control system employing both pattern analysis by neural networks, as well as statistics and color vector analysis. Mapping of high-dimensional input vectors to lower- dimensional maps in a topological order-preserving manner by these advanced control systems can be used to track to performance of a flotation process on a continuous basis, which is highly advantageous when monitoring banks of flotation cells.
  • the computer controller used in the system of the present invention is preferably a personal computer or workstation, with a associated display device (CRT screen) and input/output device (keyboard or touch-sensitive screen).
  • the controller may be located at the froth flotation machine or at a remote location such as a central control room in a plant.
  • the controller may control one or a plurality of flotation machines at a single or plurality of sites.
  • the above-described computerized control and monitoring system for froth flotation equipment provides a comprehensive scheme for monitoring and controlling a variety of input and output parameters as well as a plurality of operational parameters resulting in greater efficiency, optimization of operation, and increased safety.
  • FIGURES 1 A - D are schematic sectional views of flotation cells and flotation columns with which the monitoring and control system of the present invention is used,
  • FIGURE 2 is a schematic view of the monitoring and control system for a flotation machine in accordance with the present invention
  • FIGURE 3 is a schematic view of a preferred monitoring and control system employing a LIBS or LIMS sensor system in accordance with the present invention
  • FIGURE 4 is a schematic view of a monitoring and control system employing a LIBS or LIMS sensor system in accordance with the present invention
  • LIBS or LDVIS sensor for monitoring the composition and particle size of a dry or dewatered process flow according to the present invention
  • FIGURE 5 is a schematic view of a monitoring and control system employing a LIBS or LIMS sensor for monitoring the composition and particle size of a dry or dewatered process flow according to the present invention
  • FIGURES 6A-B are schematic views of a monitoring and control system employing a LIBS or LIMS sensor for monitoring a wet or moist process stream in accordance with the present invention
  • This invention relates to methods and apparatus for automatically controlling, operating, and monitoring flotation machines using "intelligent” computer controlled systems and remote sensing devices
  • intelligent is meant the use of computerized control methods including but not limited to neural networks, genetic algorithms, fuzzy logic, expert systems, statistical analysis, signal processing, pattern recognition, categorical analysis, or a combination thereof to analyze input in terms of one or more self-generated, continuously updated, internal models, and to make changes in operating variables as suggested by the models
  • flotation machine is used in its most general sense, being inclusive of traditional flotation cells, or flotation columns, wherein flotation may be accomplished by a variety of means, including air, ultrasound, magnetic or electrical fields, or a combination thereof
  • flotation machine in the context of the present invention may refer to a single cell or column, or to a bank of cells or columns
  • FIGURE 1 A a common flotation cell is shown at 10
  • Flotation cell 10 includes an impeller 12 mounted centrally for rotation about a vertical axis adjacent, but spaced from the bottom of receptacle 14, and having a pulp feed trough 16 from which a feed tube 18 extends downwardly to a position just outside a stabilizer 20 Conditioning agents are received through the lower end of pipe 22 Pulp is eventually discharged through outlet 24
  • Figure IB depicts a flotation cell wherein an injection device 30 is mounted to expel a two-phase gas-liquid mixture into the cell
  • FIGURE IC shows this cell mounted for operation in a bank of cells
  • FIGURE ID shows a typical flotation column 32 contemplated for use with the present invention
  • Flotation column 32 comprises a column 33 provided with a source of aeration 34 and wash water 35
  • Aeration bubble generation
  • Wash water is usually added from an array of perforated pipes located just below the froth overflow lip
  • Feed 36 is introduced about one- third of the way down form the top of column 33, and descends against the rising bubbles from aeration source 34
  • Froth concentrate 37 overflows the top column lip, while tailings 38 exit from the bottom of the flotation column
  • flotation machines of the type discussed above and in the prior art are provided with one or more sensors for the sensing of one or more parameters related to the processes and operation of the flotation machine
  • a compute ⁇ zed control system which may be located at the flotation machine, near the flotation machine, or at a remote location from the flotation machine is provided for interaction with the sensor or sensors in the flotation machine
  • This computer control system includes a control computer and one or more control devices which are actuated in response to a command signal from the control computer
  • the response of the control system will preferably be based both on sensor input and on a series of expert rules, determined initially in advance and continually updated based upon the control system's own analysis of its performance.
  • the controller will generate and continuously update its own "process model,” using the data inputs described and one or all of several advanced analysis techniques, including neural networks, genetic algorithms, fuzzy logic, expert systems, statistical analysis, or a combination of these.
  • the control system will have the ability to independently select the best analysis technique for the current data set.
  • the computer control system will actuate one or a plurality of control devices based on input from one or more monitoring sensors so as to provide real time, continuous, operational control.
  • the control system may include a monitoring system for data logging, preventative maintenance, or failure and wear prediction.
  • the control system may additionally include diagnostics relating to the condition of the equipment.
  • FIGURE 2 a schematic is shown depicting examples of the monitoring sensors, control devices, and components and features of the control system of this invention.
  • FIGURE 2 more particularly shows a flotation machine 40 having associated therewith one or more process sensors 42 and/or one or more equipment sensors 44, including optional video cameras (or imaging devices) 46.
  • the flotation machine is associated with one or more operational control devices 48
  • the sensors 42, 44 communicate through an appropriate communications system, i.e., an analog and/or digital data acquisition interface 50 with the central control computer 52.
  • One or more control devices 48 communicate through an appropriate communications system, i.e., an analog and/or digital control output interface 54 with the central controller 52.
  • the sensors 42, 44 and the control devices 48 communicate through a single, appropriate control computer 52.
  • control computer 52 may be located on the flotation machine, near the flotation machine, or at a remote location such as a control room Computer 52 has associated therewith a display 56 for displaying data and other parameters, a keyboard 58 or other means for inputting control signals, data and the like, a memory or recorder 60, and a modem 62 for inputting and outpurting data to the control computer 52 from at least one remote location.
  • control computer 52 receives a variety of inputs which have been categorized generally in terms of (1) information stored in memory when -l i ⁇
  • the outputs from the control computer may be generally categorized as (1) data stored in memory 60 associated with the control computer 52; (2) operational control of the flotation machine; and (3) real time information provided to the operator at the monitor 56 associated with the control computer 52.
  • Table 1 The various inputs and outputs are summarized in the following Table.
  • Examples of information originally stored in memory include information relating to the operation and maintenance of the flotation machine and operator training information, all of which will be readily available to an operator on display screen 56 associated with control computer 52
  • Examples of information programmed at the site where the flotation machine is to be used include the operating ranges, equipment parameters, and desired feed parameters, along with other site-specific data and environmental factors Input into the control computer also includes various process models, process controls, and guidelines These models and goals may be either stored in memory or programmed at the site as appropnate
  • a further important feature of the present invention is the large number of process and equipment sensors 42, 44 which sense a variety of aspects relating to the flotation machine, its operations, and its feed, tailings, and float streams Particularly important are sensors relating to rate of chemical addition, power consumption, aeration rate, and froth layer thickness
  • Other process parameters which may be sensed include, but are not limited to the bubble loading, volume or mass flow rates into the feed, concentrate, froth, or tailings streams, the air flow rates into the feed, concentrate, froth, or tailings streams, the density of the feed, concentrate, froth, or tailings streams, the chemical or mineralogical composition of the feed, concentrate, froth, or tailings streams, the pulp or froth levels, the particle size, concentration, and distribution of solids in the feed, concentrate, froth, or tailings streams, the bubble size, color, and distribution in the feed, concentrate, froth, or tailings streams, the pH of the feed, concentrate, froth
  • Patent No 5,379,103 all of the contents of which are incorporated herein by reference
  • An example of a suitable apparatus for sensing LLMS is the LASMA Laser Mass Analyzer available from Advanced Power Technologies, Inc of Washington, D C
  • a preferred embodiment employing a laser spectroscopy-based sensor is described in detail hereinafter with reference to FIGURES 3-6
  • one or more microphones, single-axis accelerometers or multi-axis accelerometers are positioned on or near the flotation machine
  • Acoustic emissions emanating from the machine, including sub-sonic, sonic, and ultrasonic waves, are detected either directly by accelerometers, or by microphones as they are transmitted through the air
  • Acoustic emissions are converted to electromagnetic signals and digitized for processing Processing may include, but is not limited to, Fourier transformation, fast Fourier transformation and wavelet transformation
  • the signal is known to characterize changes in the process taking place in the flotation machine
  • a stochastic model relating the acoustic emission signal to the process and the machine's performance is typically too complex to be useful Therefore, the transformed emissions signal is preferably used as an input to an advanced control system, as desc ⁇ bed hereinafter where it may be used in a neural network or other heuristic modeling system to control the performance of the machine and the flotation process
  • Suitable techniques for communication among the sensors, control computer, and other components include hard-wired electncal systems, optical systems, RF systems, acoustic systems, video systems, and ultrasonic systems
  • the computerized monitoring and control system of this invention may utilize the aforementioned sensors to monitor various parameters with respect to time and thereby provide a detailed historical record of the flotation machine operation 66
  • This record may be used by the control computer to model flotation machine operation, adjust models for flotation machine operation, or generally learn how the flotation machine behaves in response to changes in various inputs
  • operating data may be retrieved from the memory of a computer local to the flotation machine or remotely
  • the data may be displayed in real time while the flotation machine is operating using monitor 56, or as a historical record of some p ⁇ or operating sequence
  • This record may also be used to provide a data log, provide trending and preventative maintenance information, predict failure, and predict machine wear 68
  • Pre-formatted reports may present the retrieved data to show information such as operating hours, alarms generated, number of starts, number of trips, electncal power used, maximum and minimum values for measured variables, total feed processed, and the like Using the operating data, the flotation equipment manufacturer may recommend
  • Controller 52 preferably communicates through standard communication cards used with personal computers or workstations As such, Ethernet, RS-232, and modem capabilities exist for the operator's use The present invention therefore allows a given plant to collect flotation machine operating data through a plant-wide Ethernet or other network
  • the present invention may communicate with other process devices not supplied by the manufacturer In this way the operator uses the control and monitoring system of this invention to gather information on a larger portion of the process
  • Suitable software for this activity includes operator screens for data display, and message displays for operating assistance, and may also include an on-line operation and maintenance manual
  • the operator may also control and optimize the performance of the flotation machine through the plant network
  • the operating parameters as descnbed below may also become part of an overall Supervisory Control and Data Acquisition (SCADA) system or Distributed Control System (DCS)
  • SCADA Supervisory Control and Data Acquisition
  • DCS Distributed Control System
  • SCADA system or DCS microprocessor devices convert plant measurement and status inputs into computer data for logging and transmission to higher level processors
  • the SCADA system or DCS therefore connects to many controllers and field devices to gather information and make global decisions Supervisory, expert controllers make strategic decisions for the operation of a process unit or plant and send out set points to dedicated controllers which will make the changes to actuators and ultimately the process as a whole
  • a further important feature of this invention is that in response to the one or more parameters sensed by the sensors 42, 44, the operation of
  • the response of the system is based on a series of expert rules, determined initially in advance and continually updated based upon the control system's own analysis of its performance.
  • the control system will generate and continuously update its own "process model" using the sensor inputs described and the above-mentioned analysis techniques.
  • the control system may have the ability to independently select the best analysis technique for the current data set. While controller 52 may operate using any one or more of a plurality of advanced computerized control methods, it is also contemplated that these methods may be combined with one or more of the prior art methods, including feed forward or feedback control loops. Feed forward is where process and machine measurements (or calculated, inferred, modeled variables normally considered ahead of the machine in the process) are used in the controller 52 to effectively control the operation of the flotation machine.
  • Feed forward schemes inherently acknowledge that the conditions and state of the feed material to the flotation machine change over time and that by sensing or calculating these changes before they enter the flotation machine, control schemes can be more effective than otherwise might be possible.
  • Feedback is where measurements and calculated values that indicate process performance and machine state are used by controller 52 and the control scheme contained therein to stabilize the performance and to optimize performance as feed conditions changes and machine performance changes in reference to set points and optimization objectives.
  • Process and machine models are embedded in controller 52, as are methods to evaluate the models to determine the present and future optimum operating conditions for the machine. Optimum conditions are specified by flexible, objective functions that are entered into the controller 52 by the operators or plant control system that is dealing with plant-wide control and optimization.
  • the models contained therein are adaptive in that their form or mathematical representation, as well as the parameters associated with any given model, can change as required. These models include, but are not limited to first principles and phenomenological models, as well as all classes of empirical models that include neural network representations and other state space approaches. Optimization is accomplished by combining the contained knowledge of the process and machine through these models with expert system rules about the same. These rules embody operational facts and heuristic knowledge about the flotation machine and the process streams being processed.
  • the rule system can embody both crisp and fuzzy representations and combine all feed forward, feedback, and model representations of the machine and process to maintain stable, safe, and also optimal operation, including the machine and the process. Determination of the optimum operating states includes evaluating the model representation of the machine and process.
  • the adaptive control system of this invention uses one or a combination of internal and/or external machine and/or process variables to characterize or control the performance of the flotation machine, in terms of the desired process outputs.
  • the control system continually updates its knowledge of the process, so that its control performance improves over time.
  • the advanced control system of the microprocessor may actuate one or more process and/or equipment control devices 48 to control operations.
  • the operational outputs from the central controller 52 may be processed though a control output interface 54.
  • the control devices will be actuated if certain sensed parameters are outside the normal or preselected flotation machine operating range.
  • This operating range may be programmed into the control system either prior to or during operation.
  • operational parameters which may be adjusted include but are not limited to volume or mass flow rates into the feed, concentrate, froth, or tailings streams; the induced or forced air flow rates into the feed, concentrate, froth, or tailings streams; the pulp or froth levels; the particle size, concentration, and distribution of solids in the feed, concentrate, froth, or tailings streams; the bubble size, bubble volume and bubble distribution in the feed, concentrate, froth, or tailings streams; the pH of the feed, concentrate, froth, or tailings streams; the rate of addition of flotation reagents, including frothing agents, collecting agents, promoting agents, depressing agents and the like; the regional pressures and flow patterns within the flotation machine; the agitation speed in the machine; the position and orientation of a froth crowding device; the position and orientation of a draft tube; the position and orientation of an agitator; the position and orientation of a disperser
  • other outputs include the real time status of various parameters at the flotation machine.
  • the operator may use the computerized control and monitoring system of the present invention to diagnose the present condition of the equipment, order spare parts (a modem/fax 66 may be included for spare parts ordering), or obtain a read-out as part of a SCADA system or DCS as described above.
  • a particularly preferred embodiment of the present invention employs an imaging system comprising video cameras or the like 46 producing images which are converted to data usable by the process models of the present invention.
  • Flotation plant operators currently use visual observation of the color and consistency of flotation froths to estimate the performance of a circuit. Automation of the visual analysis of froth compositions would provide greatly enhanced process control.
  • a description of a video sensor system for use in mineral processing operations is described in by J.M. Oestreich, et al., Minerals Engineering,
  • the color sensor system described therein comprises a color video camera, a light source, a video-capture board, a computer, and a computer program that compares measured color vector angles to a previously stored calibration curve.
  • Several cameras may be connected to a single color sensor computer or a single camera may simultaneously observe several locations using a network of fiber-optic cables.
  • This preferred embodiment of the present invention may further comprise an advanced control system employing both pattern analysis by neural networks, as well as statistics and color vector analysis.
  • gray level dependence matrix methods are used to extract statistical features form digitized images of froths. These statistical features constitute a compact set of the essential data contained in the original image, which can then be related to the metallurgical parameters of the flotation process by means of neural nets.
  • Either supervised neural nets, such as learning vector quantization systems, unsupervised nets, such as self-organized mappings, or a self- organizing neural net which can map high-dimensional input vectors to lower-dimensional maps in a topological, order-preserving manner are used.
  • Topological maps have the advantage that they can be used to track the performance of flotation processes on a continuous basis, as opposed to the discrete classification by other classification paradigms. For example, when considering a process system consisting of a bank of flotation cells, the process could be monitored by means of a characteristic profile on a two-dimensional feature map, which would enable the early detection of deviation from optimal conditions by intelligent automation systems through comparison of the actual profile of the system with an ideal or optimal profile.
  • both viscosity and mobility of froths may be recorded and analyzed by visual means.
  • a series of modules are used to monitor different features with a high degree of accuracy.
  • a machine vision system based on the interpretation of visual features of froth structure has a modular structure, in which one module will distinguish between froths based on differences in morphology, a next module will base the distinction on froth mobility, another will extract chromatic information, another average bubble size, and so on.
  • the intelligent control system shown generally at 110 includes one or more laser-induced breakdown spectroscopy sensors (LIBS sensors) and/or laser-induced mass spectroscopy sensors (LIMS sensors).
  • LIBS and LIMS sensors are particularly useful in the determination of elemental composition in situ, that is, without the need for removal of a sample for analysis at a separate location.
  • LIBS and LIMS sensors are particularly useful in the determination of elemental composition in situ, that is, without the need for removal of a sample for analysis at a separate location.
  • X-ray analyzers have in fact been used to determine concentration of certain elements in flotation flow streams, but require removal of a sample and analysis at a separate location. Each analysis generally requires at least fifteen to twenty minutes.
  • such analyses must necessarily be discrete measurements, and thus cannot provide on-going (that is, continual), real-time, composition determinations.
  • control system 110 allows fast, discrete or continuous, real-time analysis.
  • the general configuration of the intelligent control system according to the present invention 1 10 comprises the control computer 112 described in detail above, receiving data from an LIBS sensor 114.
  • An LIBS-type sensor suitable for use with the present invention is described in aforementioned U.S. Patent No. 5,379,103 to Zigler. Such sensors are capable of measuring the percent concentration of one or more elements in a mixture.
  • Controller 112 actuates at least one control device 1 16 in response to the data received from the LIBS sensor 114 and an internal process model as described in detail above.
  • Control device 116 affects an operational parameter of the processing system 118 containing a multi-component mixture 120.
  • LIBS sensors are particularly suited for determining elemental composition in essentially dry or dewatered solids or froths.
  • processing systems are those which have sample streams which do not need to be dry or dewatered, including, but not limited to, thickeners, filters, centnfuges, analysis of the molten metal or slag streams of smelting furnaces, chemical process solutions, and the like
  • FIGURE 4 A particularly preferred embodiment using LIBS sensors in conjunction with the intelligent control system according to the present invention is shown generally at 210 in FIGURE 4
  • This embodiment exemplifies analysis and control of samples which do not require dewatenng Crushed ore 212 for separation by at least one froth flotation machine 214 is moved along belt 216 to the grinding apparatus 218
  • the ore is conditioned or stored in conditioning tank or feed box 222
  • Reagents may be added to the gnnding apparatus 218 and/or to the conditioning tank/feed box 222 via reagent addition system 224
  • the ground, conditioned material is then subjected to froth flotation in at least one flotation machine 214
  • LIBS sensor 226 analyzes the composition of one or more constituents of the crushed ore 212, and communicates these data to the intelligent controller
  • the controller uses these data as input to a computer program which uses neural network and pattern analysis to characterize the sample and estimate its composition in terms of chemical compounds or minerals contained
  • the controller may then send signals to the gnnding apparatus 218, to the reagent addition system 224 to make adjustments to the rate of reagent addition, or it may actuate at least one control device 230 affecting the operational parameters of the froth flotation machine
  • operational parameters include, but are not limited to, the impeller speed, the aeration rate, the froth wash, flow rate, the various levels of each phase, the feed rate, and the like
  • FIGURE 5 a second preferred embodiment using LIBS sensors in conjunction with the intelligent control system of the present invention is shown generally at 231
  • the LIBS sensor performs an analysis of a few key elements in dry or dewatered samples, for example the concentration of copper, molybdenum, iron, silica, and magnesium in copper flotation concentrates
  • LIBS sensor 232 performs an analysis of a few key elements in dry or dewatere
  • the above-desc ⁇ bed embodiments are directed to analysis of essentially dry or dewatered samples Such embodiments are particularly useful in that the analysis is fast, and provides real-time data with respect to a process flow
  • wet samples are dewatered and analyzed to provide data for the intelligent control system
  • This embodiment still provides fast, real-time analysis
  • LIBS sensor 312 senses a sample stream 314 from conditioner tank/feed box 316
  • LIBS sensor 318 senses a sample stream 320 from tailings 322 from froth flotation machine 324
  • Data from each sensor are communicated to the control computer 326, which in turn affects the operational parameters of the froth flotation system by actuating vanous control devices as described above
  • each sample stream is first passed through the system 340 as shown in FIGURE 6B
  • the system 340 comprises the sample feed 320, 322

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Abstract

L'invention porte sur un système informatisé 'intelligent' (110) et le procédé associé servant à contrôler, diagnostiquer, exploiter et commander les différents paramètres et processus de machines de flottation (40). Le système de gestion par ordinateur agit sur au moins un ou plusieurs dispositifs de commande (48) en fonction des signaux d'entrée fournis par un ou plusieurs détecteurs de contrôle (42, 44) permettant d'assurer en continu et en temps réel la commande des opérations. La réponse du système de commande se base sur un modèle de processus propre au système qui à son tour se fonde sur les indications des détecteurs et sur une ou plusieurs techniques d'analyse avancées incluant de manière non limitative: les réseaux neuroniques, les algorithmes génétiques, la logique floue, les systèmes experts, l'analyse statistique, le traitement des signaux, la reconnaissance des formes, l'analyse catégorielle, et leurs combinaisons. Les paramètres de processus ou de fonctionnement présentant un intérêt particulier sont le débit et la quantité des additions de réactifs chimiques, l'épaisseur de l'écume, la consommation d'énergie et le débit d'aération. Dans une réalisation préconisée, l'appareil est une machine de flottation comportant au moins un détecteur vidéo (46) fournissant des signaux d'entrée qui sont analysés par le modèle de processus résultant d'une combinaison de méthodes statistiques et de réseaux neuroniques. En fonction de cette analyse au moins un signal de sortie peut être produit pour activer un dispositif de commande (48) variables d'exploitation selon les suggestions du modèle de processus. Dans une variante encore plus recommandée, l'appareil est une machine de flottation munie d'au moins un spectromètre laser (114) fournissant des signaux d'entrée relatifs à la composition en éléments des courants entrants (alimentation) et sortants (effluents).
EP97925729A 1996-05-31 1997-05-22 Procede et appareil de commande de machines de flottation Withdrawn EP0918566A1 (fr)

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CA2257158A1 (fr) 1997-12-04

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