Decision support system for hydrometallurgical processing

As one of the alternative technological paths for copper recovery, hydrometallurgy has experienced high use intensity and a significant impact due to its ability to process ore with average and low grades at competitive prices compared to other metallurgical paths. In spite of instrumentation in pyrometullurgical and concentrators plants, developments in agglomeration and heap leaching instrumentation has not reached the required level for a fully automated control system. Variables such as agglomerates moisture content, size, shape, flowability, and internal and superficial moisture in heaps are difficult to measure in real time hindering the implementation of an automated control system.Since closing an automated feedback loop is not possible, a novel and powerful Hydrometallurgical Decision Support System (HDSS) has been developed that recommends control actions to operators of primary and fine crushing, agglomeration and heap leaching in an integrated manner. Also, the HDSS, which is connected to the real time plant information system, gathers the information by sensors and laboratory analyses to suggest to the metallurgist both curing and leaching rates, and if he approves, this new rates will be informed on the leaching operators interface. The HDSS main goal is to stabilize and increase the plant production while minimizing the energy consumption.To assess the HDSS performance, different strategies commonly used by the operators against the HDSS recommendations have been simulated. Results show that the HDSS achieves the proposed goal, decreasing the overall specific energy consumption and stabilizing the plant operation.