7
2022, and the lead circuit and entire flotation plant since
May 2023 at Buick mill.
Progress is also made to reducing the use of several
reagents including xanthate and cyanide, by automati-
cally adding potent and selective reagents and effective iron
depressant which can partially replace them. In turn, using
these reagents this way is made possible by the expert con-
trol system designed around them.
Buick mill has effectively become an advanced commer-
cial flotation laboratory with PI system recording all mill
data on all mill’s process parameters, reagents, VisioFroth ™
bubbles and XRF online assays. All the recorded data of
hundreds of variables can be generated “instantly” for any
specific period in an ODBC database format for analysis
and modeling.
The expert control system provides a powerful envi-
ronment to further develop the Buick Mill, can effectively
audit ores, processes, operations, and instrumentation and
maintenance towards continuous improvement. It is already
designed around utilizing reagents to control the flotation
based on thermodynamic and kinetic fundamentals, mean-
ing that additional reagents can be tested for similar roles
with minimal reconfiguration. The system needs little more
than to know that the role of a reagent is to, for example,
collect Zn to test the reagent to its limit in the plant as a
Zn collector.
Deep ML in Digital One expert flotation control
detects sharp spikes or drops of lead, zinc and copper grades
in mill feed whenever occurring, logs in and remembers
process parameters at that moment notably froth depths,
then waits until “seeing” froth depths spike or sudden drops
to remove froth accordingly to the previous recorded froth
depths. This increases expert control run time and metal
recoveries instead of operators disengaging optimization
and resetting froth velocities and back to expert control.
It’s a breakthrough, solves a major challenge Buick mill
and today’s mills face, and can lead to limitless applica-
tions of knowledge-based ML on the production line and
dynamically. Several such cases and applications are cur-
rently on plant trials.
The wholly digital control system means that any
aspect of the mill can potentially be built into this system.
There are plans to pursue expert grinding and expert filtra-
tion controls as well, both of which targeted at reducing
operating expenses related to these unit operations while
maximizing recovery. It is primarily because of the success
we have achieved so far with Digital One that these oppor-
tunities are made seen and available.
REFERENCES
[1] Mang, W., Steimel, A., Deml, A., Mangogna, B.,
Powell, N., Claremboux, V., Constance, T., Sampayo,
G., and T. Bhambhani (2024), “Development,
Implementation, and Implications of Second Modern
Flotation Reagent System at Doe Run’s Buick Mill,”
in 2024 SME Annual Conference Technical Program,
February 25–28, Phoenix, AZ, Society of Mining,
Metallurgy &Exploration.
[2] Mang, W., Steimel, A., Deml, A., Mangogna, B.,
Dix, J., Yap, E., McKay, J., and C. Romrell (2024),
“Digital One Enterprise Expert Operating System on
Production Line at Doe Run’s Buick Mill – Expert-
Control of Flotation, Grinding and Things (EoT),”
in 2024 SME Annual Conference Technical Program,
February 25–28, Phoenix, AZ, Society of Mining,
Metallurgy &Exploration.
[3] Mang, W., Steimel, A., Deml, A., and B. Mangogna
(2024), “Robust Expert Control of Entire Pb/Zn/Cu
Flotation Plant for Complex Ores based on Dynamic
Multivariant Response Surface Methodology,
Thermodynamics and Kinetics of Flotation and
Reagents at Doe Run’s Buick Mill,” in XXXI IMPC-
International Mineral Processing Congress, September
29-October 3, Washington, DC, Society of Mining,
Metallurgy &Exploration, in preparation.
2022, and the lead circuit and entire flotation plant since
May 2023 at Buick mill.
Progress is also made to reducing the use of several
reagents including xanthate and cyanide, by automati-
cally adding potent and selective reagents and effective iron
depressant which can partially replace them. In turn, using
these reagents this way is made possible by the expert con-
trol system designed around them.
Buick mill has effectively become an advanced commer-
cial flotation laboratory with PI system recording all mill
data on all mill’s process parameters, reagents, VisioFroth ™
bubbles and XRF online assays. All the recorded data of
hundreds of variables can be generated “instantly” for any
specific period in an ODBC database format for analysis
and modeling.
The expert control system provides a powerful envi-
ronment to further develop the Buick Mill, can effectively
audit ores, processes, operations, and instrumentation and
maintenance towards continuous improvement. It is already
designed around utilizing reagents to control the flotation
based on thermodynamic and kinetic fundamentals, mean-
ing that additional reagents can be tested for similar roles
with minimal reconfiguration. The system needs little more
than to know that the role of a reagent is to, for example,
collect Zn to test the reagent to its limit in the plant as a
Zn collector.
Deep ML in Digital One expert flotation control
detects sharp spikes or drops of lead, zinc and copper grades
in mill feed whenever occurring, logs in and remembers
process parameters at that moment notably froth depths,
then waits until “seeing” froth depths spike or sudden drops
to remove froth accordingly to the previous recorded froth
depths. This increases expert control run time and metal
recoveries instead of operators disengaging optimization
and resetting froth velocities and back to expert control.
It’s a breakthrough, solves a major challenge Buick mill
and today’s mills face, and can lead to limitless applica-
tions of knowledge-based ML on the production line and
dynamically. Several such cases and applications are cur-
rently on plant trials.
The wholly digital control system means that any
aspect of the mill can potentially be built into this system.
There are plans to pursue expert grinding and expert filtra-
tion controls as well, both of which targeted at reducing
operating expenses related to these unit operations while
maximizing recovery. It is primarily because of the success
we have achieved so far with Digital One that these oppor-
tunities are made seen and available.
REFERENCES
[1] Mang, W., Steimel, A., Deml, A., Mangogna, B.,
Powell, N., Claremboux, V., Constance, T., Sampayo,
G., and T. Bhambhani (2024), “Development,
Implementation, and Implications of Second Modern
Flotation Reagent System at Doe Run’s Buick Mill,”
in 2024 SME Annual Conference Technical Program,
February 25–28, Phoenix, AZ, Society of Mining,
Metallurgy &Exploration.
[2] Mang, W., Steimel, A., Deml, A., Mangogna, B.,
Dix, J., Yap, E., McKay, J., and C. Romrell (2024),
“Digital One Enterprise Expert Operating System on
Production Line at Doe Run’s Buick Mill – Expert-
Control of Flotation, Grinding and Things (EoT),”
in 2024 SME Annual Conference Technical Program,
February 25–28, Phoenix, AZ, Society of Mining,
Metallurgy &Exploration.
[3] Mang, W., Steimel, A., Deml, A., and B. Mangogna
(2024), “Robust Expert Control of Entire Pb/Zn/Cu
Flotation Plant for Complex Ores based on Dynamic
Multivariant Response Surface Methodology,
Thermodynamics and Kinetics of Flotation and
Reagents at Doe Run’s Buick Mill,” in XXXI IMPC-
International Mineral Processing Congress, September
29-October 3, Washington, DC, Society of Mining,
Metallurgy &Exploration, in preparation.