Advanced Control Tools

Advanced process control

The Outotec ACT (Advanced Control Tools)
solution is a complete process optimization
concept comprising design, implementation,
maintenance and all the necessary hardware
and software. It combines your local process
knowledge with our solid experience in process
optimization, helping you get the most out of
your plant.
Strengthen your economic performance
Our optimization systems have one universal
goal: to increase the economic performance of
your plant. The major economic benefi ts come
from increased and more effi cient production
along with savings in operating costs.

Advanced control applications also bring

more stability to the process, as well as
consistency to the plant operation. Less
disturbance means less variance in process
performance. Higher availability leads to more
efficient utilization of capital; equipment is used
at full capacity all the time.
In addition to the direct economic profit, an
increase in process know-how among the plant
personnel can be achieved as they take part in
the development of the optimization system.
Enhanced plant operation also has a positive
impact from an environmental point of view
since resources are used more effectively.

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Knowledge in action
Vast expertise in the industry
Outotec has been a pioneer in the development
of process control applications. In the 1960's and
70's, when Outotec was still a part of Outokumpu,
the international metals group, we developed one
of the first continuous process control systems.
Shortly after that, higher-level optimizing controls
came into the picture.
The Outotec ACT concept takes advantage of this
renowned industry expertise and uses modern
information technology to create a powerful
process control solution tailored to your needs.

Specialists from different disciplines

Finding a successful solution for plant-wide process
optimization requires seamless co-operation between
many specialists. Outotecs strength lies in the
in-house expertise of both process and automation
engineering as well as operational know-how.

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Vast expertise in the industry

We develop and implement the ACT system in close
co-operation with the customer. Every solution is designed
individually, yet effi ciently, using a selection of standard tools.
Our tried and tested solutions range from crushing, grinding,
flotation and dewatering to the smelting and refi ning of metals.
If required, our services can also include maintenance and
operational support as well as further development of the
system. Increase your process knowledge and put it into action.

Consistent way to
control your process

Ability to optimize
the process

+ Increased
recovery

+ Higher quality
+ More stability

ACT Solution

+ Savings in

operating costs

The Outotec ACT

solution improves
the plants economic
performance through
increased knowledge
and process optimization.

+ Increased capacity

Logical approach
to process control

Increased
knowledge

Improved
economic
performance

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Case 1: Grinding
Optimizing the grinding circuit
Efficiency in the grinding circuit strongly improves the overall
performance of a concentrator. Since grinding accounts for
a large proportion of operating costs and has a strong impact on
downstream processes such as fl otation, the grinding control
system is one of the most important factors in concentrator
performance.
For years, Outotec has been helping customers optimize their
grinding circuits by providing PSI particle size analyzers and
MillSense mill charge analyzers, to evaluate the status and
performance of the process. More recently, we have consolidated
our strong grinding know-how to provide an advanced grinding
control solution.
When the solution is applied, the variation of process parameters
is reduced, the desired particle size distribution is maintained and
the throughput of the mill is optimized. This ensures the
cost-effective, trouble-free and effi cient operation of grinding
circuits as well as steady feed to downstream processes.

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Advanced grinding control

The control strategy is robust and
effective, and has proven its reliability in
several installations. The most suitable
control strategy for each circuit is
tailormade on the basis of process data
analysis, available instrumentation and
current operating methodologies. As the
first step of control, on-line data is
validated and used for monitoring the
grinding circuit status and its performance.
Primary control actions are taken in
order to stabilize the process parameters
and prevent disturbances such as the
overloading of the mill or an unstable
circulating load.

Optimal
throughput
Desired product
quality
Less
disturbance

Furthermore, the throughput of the

circuit is optimized based on the defined
criteria of product particle size and
operating costs. By utilizing Outotec
MillSense, control can also be based
on a volumetric load to optimize grinding
efficiency. This is especially useful in
SAG/AG mill applications.
With our advanced grinding control
solution you can reliably maximize the
performance of your mills.

Data
validation
Condition
estimation
Circuit
stabilization
Optimization

Our applications cover the whole

grinding process.

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Case 2: Flotation
Optimizing the flotation circuit
Since Outotec was formerly part of a mining company and
continues to be the leading supplier of analyzers and flotation
equipment, a large amount of flotation expertise has been
concentrated in our engineering teams. Outotec's optimization
solutions cover practically every type of flotation.
Complex chemistry, high non-linearity and the signifi cant effect
on the economic performance of the plant make fl otation control
a challenging task. Numerous customers have entrusted their
flotation optimization to us; our solutions significantly improve the
metallurgical results and reduce costs, leading to a payback time
of only a few months.

Advanced grade control

Advanced grade control optimizes the metallurgical performance
of flotation unit operations as well as the whole process.
Optimization is based on criteria consisting of target values for
grades and recoveries. The use of other factors, for example
economic functions and separation indexes, is determined case
by case.
On-line validation of process data ensures the correct and reliable
operation of process models and control actions. Balance
calculations and experiential models determine the process status,
whereas process monitoring verifi es the functioning of base layer
controls and process equipment. Process stability is always assured
before optimization, which then drives the process towards the
optimal recovery and concentrate grade.

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Securing exact levels

Keeping an eye on froth

The precision of the level control contributes

directly to the consistency of metallurgical
results. Random variation in the froth bed
thickness results in a decreased metallurgical
performance. The widely used separate PID
controllers are often unsatisfactory for this
task since slurry level controls are highly
interconnected; control action in one cell
causes disturbance to the following cell.

Metallurgists have always wanted an

effective means of automatically measuring
and controlling froth properties as the
balanced froth dynamics maximizes the cell
efficiency. Our respond to this need is an
advanced froth control, which uses
information measured by the FrothMaster
instrument. Froth flow is controlled bya
hierarchical, multivariable algorithm.
Additionally, the system is able to detect
abnormal situations in the froth, such as froth
collapse, and determine corrective action..

To solve this problem, Outotec has developed

the EXACT-level control solution.
It simultaneously monitors the entire flotation
line and effectively compensates for the
process disturbances before levels are
affected. Independence of flotation line
configuration and joint operation with
traditional PID controllers allow easy
implementation to existing and new
concentrators. An automatic tuning component
identifies process parameters on-line making
the use and maintenance of the system
very simple. Direct improvements in slurry
level control lead to significant benefits in
flotation performance.

EXACT-LEVEL CONTROL IN ACTION

More accurate control
Reduced valve travel
Faster disturbance
rejection

The speed at which the froth is recovered over

the lip of the cell has a very direct and
consistent influence on the grade and the
recovery of the circuit. Attained controllability
of froth enables totally new grade and recovery
optimization, as froth speed is used jointly with
the on-stream analyses to provide an enhanced
and responsive cell-specific optimization system.
In some applications, other froth parameters,
such as froth stability and froth color, are
included in the optimization.

Elimination of
unnecessary safety
margins
More consistent
concentrate grade
Smooth feed to downstream processes
Better performance in
plant start-up
Increased recovery

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An advanced control project

Close co-operation with the
plant personnel at every step
of the automation project
ensures best results.

Together towards success

The Outotec ACT solution is created either as a turn-key
project or, which is more recommended, in co-operation
with the plant personnel. Local process knowledge should
never be underestimated and, based on our experience,
the personnels strong involvement in the development of
the solution leads to the best results. As a result of
numerous successful applications, we have developed
systematic procedures for carrying out the project.

Process review
The characteristics of the plant are fi rst reviewed in detail,
providing the required background information for the
development of the solution. Processes are different as
there are always special factors relating to chemistry,
mineralogy and equipment for example.
Even the best possible control strategy will not perform well
unless the equipment or PID loops work correctly. We
therefore examine the need for control loop tuning, the
limitations of instrumentation, typical operating
methodologies and the special features of the process.

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Designing the solution

Putting it into action

Our specialists and plant engineers jointly create

the control strategy. The customers
metallurgists and automation engineers have
strong practical knowledge of the process and
automation system in question.

In the implementation phase, the control application

is built, tested and tuned in the plant. The operating
environment is also carefully designed in accordance
with the existing operator interface style so as to
remain familiar to the operators.

Correspondingly, our experts provide case

examples and propose solution alternatives for
process optimization on the basis of experience
gained from several advanced control projects.
The optimal solution is designed together to
meet the customers requirements.

The participation of the customers engineers

responsible for the Outotec ACT solution is strongly
recommended. The transfer of process knowledge is
vital for the successful maintenance and future
development of the system. New development ideas
often arise over time, as the plant personnel become
more familiar with the system. Outotecs experience
and technical support will always be available for your
assistance.

The optimal solution is designed

together with the customer.

Process & equipment review

Creating a control strategy
Implementation

Improvement in results

Feed or process changes,

knowledge increases, etc.
Tuning, maintenance,
further development

Customer

Outotec is a worldwide technology leader providing innovative and

environmentally sound solutions for a wide variety of customers in
minerals and metals processing as well as related process industries.
Outotec Oyj is listed on the OMX Nordic Exchange Helsinki.

automation@outotec.com
www.outotec.com

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