AI for flotation recovery

AI for Flotation Recovery: Case Study on Flotation Recovery Improvements

Client Profile

A major global phosphate and potash mining company faced challenges with inconsistent phosphate recovery rates in their rougher flotation circuits.

The Challenge

Inconsistent Recovery Rates

Inconsistent phosphate recovery rates in rougher flotation circuits.

Delayed Laboratory Results

Laboratory results available only every 12 hours.

Reliance on Experience

Operators relying on experience for parameter adjustments.

Improvement Goal

Goal to improve flotation plant recovery by 1% without sacrificing OEE or quality.

Process Point's Solution: Data-Driven Intelligence

Data Collection and Analysis

Gathered 5 years of historical data from multiple sources (PI, LIMS, legacy systems). Identified 57 key attributes, including lagged variables for predictive sustainability.

Advanced Modelling

Developed an ensemble model (Model A) for complex predictions. Created a leaner model (Model B) for simulating recovery. Achieved desired recovery improvement goals.

Implementation

Deployed models into the production environment. Integrated with existing systems for seamless operation. Provided training and support for end-users.

Continuous Improvement

Monitored model performance and made necessary adjustments. Conducted regular reviews to ensure alignment with business goals. Leveraged feedback for ongoing enhancements.

Results and Benefits

Our AI-powered solutions have delivered significant improvements in operational efficiency and decision-making for our clients. Here are some of the key benefits:

Improved Phosphate Recovery

Our solutions have enhanced phosphate recovery in the rougher flotation circuits, leading to increased yield and efficiency.

Advanced analytics for flotation process optimization

Real-Time Insights

We provide real-time insights and predictions, eliminating the traditional 12-hour lag in laboratory results.

Operators using data-driven decision-making tools in a high-tech control room.

Empowered Operators

Our tools empower operators with data-driven decision-making capabilities, enhancing their efficiency and effectiveness.

Conclusion

Expertise Utilized: Leveraged Process Point’s expertise in data-driven intelligence.
Optimization Achieved: Successfully optimized the client’s flotation recovery process.
Technologies Used: Applied advanced analytics and real-time monitoring.
Challenges Addressed: Solved complex industrial challenges related to mineral recovery.
Results:
- Significant improvements in mineral recovery.
- Achieved the client’s primary goal.
- Provided long-term benefits such as enhanced decision-making and operational insights.