Quantitative Methods to Support Data Acquisition Modernization within Copper Smelters

Abstract

Sensors and process control systems are essential for process automation and optimization. Many sectors have adapted to the Industry 4.0 paradigm, but copper smelters remain hesitant to implement these technologies without appropriate justification, as many critical functions remain subject to ground operator experience. Recent experiments and industrial trials using radiometric optoelectronic data acquisition, coupled with advanced quantitative methods and expert systems, have successfully distinguished between mineral species in reactive vessels with high classification rates. These experiments demonstrate the increasing potential for the online monitoring of the state of a charge in pyrometallurgical furnaces, allowing data-driven adjustments to critical operational parameters. However, the justification to implement an innovative control system requires a quantitative framework that is conducive to multiphase engineering projects. This paper presents a unified quantitative framework for copper and nickel-copper smelters, which integrates thermochemical modeling into discrete event simulation and is, indeed, able to simulate smelters, with and without a proposed set of sensors, thus quantifying the benefit of these sensors. Sample computations are presented, which are based on the authors’ experiences in smelter reengineering projects.