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RecoveryExpert™ is a turnkey recovery/flotation expert control solution that combines our industry leading PlantVision™ froth image analysis system with our highly intelligent KSX Expert System.Screen Shot 2014-07-31 at 11.11.19 AM

PlantVision™ is an image analysis system that captures HD images and video from the flotation cell and then accurately determines froth velocity, texture, stability, color, and bubble size. The live HD video is fed to the control room for general supervision, while the measured data is sent to the KSX Expert System for the precise determination of flotation cell set points. The primary function of the system is to increase throughput, while maintaining or improving recovery rates. 

The KSX expert control software works through the plant’s DCS stabilizing control system to provide the decision making capability of an entire expert operating team. Through analyzing control variables and powerful neural networks, genetic algorithms, and fuzzy logic, KSX expert control can adaptively optimize the recovery circuit based on strategies that combine the experience of our engineers and the Client’s staff (engineers, metallurgists, economists, managers, mill operators, etc.) with the advanced computing tools of artificial intelligence such as fuzzy logic, genetic algorithms, and neural networks. KSX monitors recovery, grade and downstream constraints like regrind capacity and sump levels and pumping constraints. They integrate seamlessly with image analysis software to maximize recovery during flotation at the desired final concentrate grade.

By using our best in industry flotation strategies, together with our PlantVision™ image analysis system we can provide:

  • Increased Rougher Recovery – Typical results are 1.5% to 3% increase in recovery during froth flotation
  • Improved Cleaner Grade – Produce higher grade product.
  • Optimized Reagent Usage – Reagent costs will go down with optimized use.
  • Significantly reduce start up times
  • Stabilize the flotation circuit with improved level control and elimination of disturbances (no propagation of disturbances between cells either).
  • Minimize the amount of impurities
  • Detect Faults / Cell lip detection

Screen Shot 2014-07-31 at 11.10.00 AMThe RecoveryExpert™ expert control will simultaneously optimize all set points for all cells and do so with consideration to the pulling rate for each cell, froth color; bubble size; texture; stability; concentrate sump level, tails grade, head grade, regrind mill power and cyclone pressure. It will update the results every 60 seconds. It will utilize neural networks, genetic algorithms, and fuzzy logic to create stabile, predictive, and intelligent set point changes. The speed, accuracy, and effectiveness of PlantVision™ and KSX working together to automate set points, increase recovery, and reduce reagent consumption simply cannot be beat.

Below is a very typical recovery histogram from one of our customers using our expert control solution. The total average recovery was increased by 3%, and as measured by the standard deviation,  the control provided by RecoveryExpert™ proved to be much more stabile. These on/of tests are performed according to the guidelines published here..

Results from a real-life RecoveryExpert™ customer.  In these typical results, recovery is increased by 3%. RecoveryExpert™ also has a much tighter distribution (better control) as measured by the standard deviation.

Results from a real-life RecoveryExpert™ customer. In these typical results, recovery is increased by 3%. RecoveryExpert™ also has a much tighter distribution (better control) as measured by the standard deviation. Please contact a member of our team for a full reference list and similar success stories.

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