PROCESS CONTROL
Finally , is there a distinction to be made between algorithms and AI in mineral process plant control and will AI take things to a new level ? Mahesh told IM : “ Algorithms are predefined sets of rules or equations designed to govern plant control processes . They are wellsuited for routine and predictable tasks , but they lack the adaptability to respond to changing or complex conditions . In contrast , AI leverages machine learning and neural networks to learn and improve over time . This allows AI to tackle complex , non-linear , and unpredictable scenarios , offering capabilities far beyond the static nature of algorithms .”
Yokogawa argues that AI represents a paradigm shift for the mining industry , driving progress in several key areas : “ AI systems can self-diagnose and self-correct without requiring human intervention , paving the way for more autonomous operations . Unlike traditional algorithms , AI can also model and optimise intricate processes , improving outcomes and efficiency . And AI introduces transformative capabilities such as adaptive learning , enhanced safety monitoring , and real-time optimisation , revolutionising how plants operate ."
Mining-specific use cases already highlight the unique potential of AI , driven by the distinct equipment and processes involved . Mahesh : “ As mining operations increasingly deploy AI across various aspects of process plants , logical areas
for adoption continue to expand . AI is emerging as a critical tool for addressing industry challenges , such as human resource scarcity and the growing demand for autonomous operations . At its core , AI serves as both a starting point for innovation and a pathway to fully autonomous plants . By enabling smarter , more adaptive systems , AI is poised to unlock efficiency gains and operational advancements that were previously unattainable in mineral processing .”
The Metso view – from analysers to AI
We also talked to Metso ’ s Michael Venegas , Product Head , Beneficiation & Dewatering , specifically about the role its analysers – including the Courier and PSI types – play in enabling more efficient and more automated process plants in mining .
He says they are revolutionising hydrometallurgical and mineral processing plants by enhancing efficiency and enabling greater automation . The Courier analysers use X-ray fluorescence ( XRF ) and laser-induced breakdown spectroscopy ( LIBS ) technologiesg for real-time elemental analysis of slurry streams , allowing operators to monitor metal concentrations and optimise processes like flotation and leaching . Meanwhile , PSI analysers measure particle size distribution , ensuring grinding processes operate at peak efficiency , reducing over-grinding , energy consumption , and equipment wear .
Venegas : “ These analysers integrate with advanced process control ( APC ) systems to automate adjustments to key parameters , such as reagent dosage and feed rates . This minimises human intervention , reduces manual sampling , and enhances process reliability . By providing precise control over metallurgical processes , Courier analysers maximise metal recovery while minimizing reagent usage . PSI analysers ensure grinding circuits maintain throughput and efficiency , resulting in significant energy savings .”
With reduced resource consumption and less reliance on manual sampling in hazardous environments , these tools also align with sustainability goals and improve workplace safety . Another advantage is that real-time data eliminates delays from laboratory testing , enabling immediate responses to process variations . Rapid adjustments maintain operational stability and avoid costly downtime .
Metso analysers also connect seamlessly with platforms like Metso Metrics , offering predictive maintenance and advanced analytics for comprehensive plant performance insights . Venegas : “ By delivering accurate , real-time data and enabling automation , Metso ’ s analysers are driving productivity , cost savings , and sustainability in the mining industry , positioning operations for success in an increasingly competitive and environmentally conscious landscape . They play a pivotal role in Metso
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JANUARY 2025 | International Mining 65