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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
Weishi Mang, Andrea Deml
The Doe Run Company, Boss, MO
Adam Steimel
The Doe Run Company, Centerville, MO
Randy Hanning, Brian Mangogna
The Doe Run Company, Viburnum, MO
ABSTRACT: The Doe Run Company (Doe Run), a global supplier of lead, copper and zinc concentrates, and
lead metal alloys, has been operating since December 2022 the Zn, Cu and Pb flotation circuits automatically
at its Buick Mill with Digital One enterprise expert control system. Digital One is based on thermodynamics
and kinetics of flotation and reagents, with a fundamental framework of Dynamic Multivariate Response
Surface Methodology (RSM) that can model complex, changing and seemingly stochastic Pb/Zn/Cu flotation.
Thermodynamics and kinetics of industrial flotation may be defined as consisting of reagents, bubbles, particle
characteristics and their interactions, and flotation phase equilibria as XRF process froth and tail assays. With
machine learning and a hybrid modern/traditional reagent system, Digital One effectively processes highly
varying complex ores using online data from various sensors, and soft sensors including online XRF assays
and VisioFroth bubble characteristics. With unprecedented robustness, Digital One removes the right amount
of froth at the right time to reach target rougher and final concentrate grades for varying feed grades while
optimizing mineral loading and metal recoveries. Digital One sees no boundaries in DCS, integrates all mill
processes, and operates any reagents, e. g. turning on and off modern flotation reagents to regulate any traditional
reagents such as xanthate.
INTRODUCTION
Doe Run has described Digital One Enterprise Expert
Control and Operating System (Digital One) and its appli-
cations at Buick Mill in previous publications (Mang et al.,
2024a, 2024b, 2024c). Doe Run developed Digital One
with Metso in OCS-4D ® that runs Metso’s VisioFroth ™
technology with an open architecture seeing no limits in
mill applications. Digital One, digitally immersed in any
distributed control system (DCS), can control any data
received by the DCS and manage any control in DCS
system.
This article systematically outlines the development of
flotation fundamentals in Digital One like hydrodynam-
ics, thermodynamics, kinetics, and phase equilibria of
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
Weishi Mang, Andrea Deml
The Doe Run Company, Boss, MO
Adam Steimel
The Doe Run Company, Centerville, MO
Randy Hanning, Brian Mangogna
The Doe Run Company, Viburnum, MO
ABSTRACT: The Doe Run Company (Doe Run), a global supplier of lead, copper and zinc concentrates, and
lead metal alloys, has been operating since December 2022 the Zn, Cu and Pb flotation circuits automatically
at its Buick Mill with Digital One enterprise expert control system. Digital One is based on thermodynamics
and kinetics of flotation and reagents, with a fundamental framework of Dynamic Multivariate Response
Surface Methodology (RSM) that can model complex, changing and seemingly stochastic Pb/Zn/Cu flotation.
Thermodynamics and kinetics of industrial flotation may be defined as consisting of reagents, bubbles, particle
characteristics and their interactions, and flotation phase equilibria as XRF process froth and tail assays. With
machine learning and a hybrid modern/traditional reagent system, Digital One effectively processes highly
varying complex ores using online data from various sensors, and soft sensors including online XRF assays
and VisioFroth bubble characteristics. With unprecedented robustness, Digital One removes the right amount
of froth at the right time to reach target rougher and final concentrate grades for varying feed grades while
optimizing mineral loading and metal recoveries. Digital One sees no boundaries in DCS, integrates all mill
processes, and operates any reagents, e. g. turning on and off modern flotation reagents to regulate any traditional
reagents such as xanthate.
INTRODUCTION
Doe Run has described Digital One Enterprise Expert
Control and Operating System (Digital One) and its appli-
cations at Buick Mill in previous publications (Mang et al.,
2024a, 2024b, 2024c). Doe Run developed Digital One
with Metso in OCS-4D ® that runs Metso’s VisioFroth ™
technology with an open architecture seeing no limits in
mill applications. Digital One, digitally immersed in any
distributed control system (DCS), can control any data
received by the DCS and manage any control in DCS
system.
This article systematically outlines the development of
flotation fundamentals in Digital One like hydrodynam-
ics, thermodynamics, kinetics, and phase equilibria of