Interface level regulation in an oil sands separation cell using model-based predictive control

• This paper presents an application of model predictive control in a mining extraction circuit.
• The application is bitumen extraction from mined oil sands.
• Model based predictive control (MPC) requires a model of the process.
• Details on model identification runs conducted at Suncor's extractions circuit are included.
• MPC utilizes a softsensor to measure froth–bitumen interface & manipulates underflow pump speed.

Large-scale separation cells, used in primary extraction in the oil sands industry, are integral parts of the overall process of bitumen extraction. Good regulation of the interface level between the bitumen froth and the middlings in these cells can result in a significant improvement in bitumen recovery and throughput and heavily influence process economics. This paper details a case study application of identification and design of a model based predictive controller for the separation cell process. Internal model control (IMC) and model predictive control (MPC) schemes using linear models are designed and implemented in real time on the industrial separation cell. The industrial implementation result shows that both IMC and MPC schemes provide significant benefits over the current operations which use a PID controller. The benefits include significant reduction in the variance of the interface level and underflow pump movement, resulting in higher bitumen recovery, smoother operations downstream and pump energy savings.