By: Kobus Vermeulen - Direct Sales Executive, Process Automation at Schneider Electric

Today’s mineral processing companies face almost-universal challenges, efficiently managing resources and high energy consumption, environmental compliance, barriers to technological adoption and perpetual shortage of skilled labour.

It’s a mouthful, to say the least – and there’s no surefire solution. Life and similarly business operations is after all, work in progress.  And whilst there’s no miracle intervention there are undoubtedly solutions that improve the above, and one is Advanced Process Control (APC).

With its roots traced back to the late 1950s - when computers were first used for process optimisation - APC goes beyond basic process control by employing advanced algorithms and models to improve efficiency, quality, and safety in industries such as chemical processing, oil refining, pharmaceuticals, and power generation.

In the minerals industry, APC enhances processing activities such as grinding, flotation and separation.  By continuously monitoring and adjusting operations, it reduces waste, improves recovery rates, and ensures stable production conditions.

From an environmental monitoring perspective, APC allows minerals operators to integrate this functionality into processing operations thus ensuring compliance with regulations. It’s automation at its finest.

APC also offers additional, important benefits to the minerals industry:

• Process stability which minimises process variations, resulting in improved product quality and reduced reprocessing needs, leading to further cost savings.
• Data-driven insights that leverage advanced analytics, providing actionable insights to improve decision-making and drive operational improvements.
• These solutions are adaptable to various mining operations, from small-scale sites to large industrial facilities, making them accessible across the sector.
• It also plays a crucial role in optimising the energy efficiency of concentrators, smelters, and refineries through:

·         Dynamic optimisation - continuous real-time adjustments ensure operations run at peak efficiency.

·         Predictive control: forecasting process behaviour enables proactive adjustments, reducing energy waste.

·         Minimised variability: stable operations consume less energy and reduce material wastage.

·         Feedback loops: continuous refinement of control strategies ensures long-term energy optimisation.

Cost benefits

It is safe to say that the above benefits also translate into cost savings.  In fact, implementing an APC solution at a mineral processing plant could increase revenue by $20 000 per due day to a number of factors including increased production as a result of maximised throughput and equipment utilisation.

Furthermore, revenue can be bolstered by enhanced product quality, which means there is less rework and waste.  Also, process stability allows for greater predictability in operations which, in turn, leads to improved inventory and subsequent cashflow management.

Also, APC allows for the optimised material usage which minimises waste disposal costs and creates a potential revenue stream from recyclable materials.

Importantly, APC can reduce energy usage by up to 5% per ton of production which can have a significant impact on both operational costs and environmental goals.

Schneider Electric's APC is designed to optimise industrial processes and improve operational efficiency. Our APC solutions include features such as:

• Model Predictive Control (MPC) which uses advanced model predictive control algorithms to enhance process profitability by improving quality, increasing throughput, and reducing energy consumption.
• Industry application - tailored for industries such as refining, petrochemicals, mining, and food and beverage (F&B), helping businesses address complex manufacturing challenges.
• Systems collect and analyse process data to dynamically adjust variables, ensuring optimal performance with minimal disruptions.
• Schneider Electric’s APC integrates with our vendor-neutral EcoStruxure IoT platform, enabling real-time monitoring, analytics, and optimization for smarter operations.