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Impact advanced process control

Process optimisation with measurable benefits 

Impact Advanced Process Control (APC) is designed to improve the stability and performance of mineral processing plants by coordinating how individual control loops and operating objectives work together.

In many plants, grinding, flotation and downstream circuits are controlled in isolation. This often leads to conflicting control actions, unstable operation and conservative operating setpoints. Impact APC addresses this by aligning control strategies across the circuit to support metallurgical objectives such as throughput, recovery and product quality.

The image shows a large, open-pit mine with intricate winding paths and a deep central pit.
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OPERATIONAL GAINS THAT TRANSLATE TO BUSINESS VALUE

By helping reduce process variability and coordinating control actions across the plant, Impact APC enables operations to run closer to their true constraints without sacrificing stability.

In practice, this can deliver:

  • higher and more consistent throughput
  • improved metallurgical performance and recovery stability
  • reduced operating costs through lower reagent consumption and equipment wear.

These operational improvements are designed to translate directly into sustained productivity gains and improved profitability, with benefits that are measurable and repeatable across varying ore types and operating conditions.

 

WORKING AS PART OF YOUR OPERATION TEAM

Our process control engineers work as an extension of your site team, combining metallurgical understanding with control system expertise to address real operational constraints and bottlenecks.

Rather than applying generic control templates, we analyse plant behaviour, identify sources of variability and develop strategies that adapt to changing ore characteristics and operating conditions.

These strategies can be implemented incrementally, allowing efficient testing and validation without disrupting production.

This approach enables rapid learning, practical optimisation and sustained improvements that operators and metallurgists can trust and maintain.

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Impact APC can improve grinding circuit stability and throughput by actively managing the interaction between feed rate, mill load, power draw and downstream constraints in real time.

Rather than relying on conservative setpoints and manual intervention, the system responds continuously to changing ore characteristics and operating conditions. This can result in a more stable mill, reduced excursions and the ability to operate closer to true circuit limits.

image of protein rich food including salmon

Impact APC helps improve flotation performance by coordinating control actions across flotation banks rather than treating individual cells in isolation.

Flotation circuits are inherently dynamic, with recovery and grade sensitive to changes in feed composition, air rates, froth depth and upstream stability. Impact APC monitors the behaviour of the flotation bank as a whole and adjusts operating targets to maintain stable mass pull and recovery under changing conditions.

By managing these interactions in a coordinated way, Impact APC helps:

  • reduce recovery variability
  • maintain stable froth conditions
  • respond more effectively to feed and upstream disturbances
  • support metallurgical intent across the circuit.

The result is a flotation circuit that can operate more consistently, enabling improved recovery outcomes that can be sustained over time.

 
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