Flotation Recovery Improvements Case Study
Client Profile
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
Improved Phosphate Recovery
Real-Time Insights
Empowered Operators
Conclusion
By leveraging Process Point’s expertise in data-driven intelligence, the client successfully optimized their flotation recovery process. This case study demonstrates the power of advanced analytics and real-time monitoring in solving complex industrial challenges, leading to significant improvements in mineral recovery. The implementation not only achieved the client’s goal but also provided long-term benefits through enhanced decision-making capabilities and operational insights.
