Dynamic hybrid modeling and simulation of grinding–flotation circuits for the development of control strategies

• An integrated simulator for a grinding plant and a flotation circuit is presented.
• Hybrid models are used to represent the different modes of operation of the plant.
• The simulator is calibrated with plant data gathered from different sources.
• The simulator exhibits a behavior qualitatively close to a real plant.

Process simulation is a very important tool for the design, development, analysis and optimization of technical processes in the mineral industry. The ability to simulate process behavior without the cost of test runs can prevent the loss of man-hours and production, in addition to providing a platform for the development of control tools and strategies. The usefulness of a simulator ultimately relies on how accurately the underlying mathematical model represents real behavior. In mineral processing, due to varied complexities such as strong non-linearities, variable coupling, time varying parameters, etc.; the development of accurate process models becomes an increasingly difficult task.This paper describes the modeling and simulation of the main components of a concentrator plant, the grinding and flotation circuits. A hybrid dynamic model was favored to better represent the different modes of operation and non-linearities exhibited by the plant. Industrial plant data was used to calibrate the models used in the simulator. Simulation tests show that the performance of the simulator is qualitatively similar to that of a real plant, and it can be effectively used as a tool for the design and simulation of control solutions.