Avoiding Buffer Tank Overflow in an Iron Ore Dewatering System with Integrated Control System

High water usage is necessary while ore passes through the many stages of a mineral processing plant. However, a dewatering system filters the final ore pulp product to remove the water, which is reutilized in the previous processes. This step is fundamental to reducing the fresh new water consumption. Usually, several tanks, pumps, and filters form a dewatering system—any failure or shutdowns from those components disbalance the pulp flow. The waste of many tons of water and ore products for a tailing dam is the worst consequence of a mass disbalance in a dewatering system. This paper proposes an advanced regulatory control strategy composed of cascade and override loops for a dewatering system. The main purpose is to increase the production period, even under filter failure and changes in the inlet pulp characteristics. This control strategy is evaluated using a digital model of a large-scale Brazilian iron ore processing plant. Two scenarios are investigated: the simultaneous failure of two filters and disturbances in the flow and density of the thickener. The simulation results show that the proposed control strategy could extend the period of operation of the dewatering plant under failures in the disc filters and reject significant disturbances. For the considered simulation period, the proposed solution increases the time to overflow by 72% when compared to the previous control strategy. Thus, it is possible to avoid the waste of approximately 2448.36 tons of ore pulp that would be sent to the tailings dam.