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Developing a data-driven soft sensor to predict silicate impurity in iron ore flotation concentrate

Pural Yusuf Enes

Physicochemical Problems of Mineral Processing

2023

Vol. 59, iss. 5

art. no. 169823

Soft sensors are mathematical models that estimate the value of a process variable that is difficult or expensive to measure directly. They can be based on first principle models, data-based models, or a combination of both. These models are increasingly used in mineral processing to estimate and optimize important performance parameters such as mill load, mineral grades, and particle size. This study investigates the development of a data-driven soft sensor to predict the silicate content in iron ore reverse flotation concentrate, a crucial indicator of plant performance. The proposed soft sensor model employs a dataset obtained from Kaggle, which includes measurements of iron and silicate content in the feed to the plant, reagent dosages, weight and pH of pulp, as well as the amount of air and froth levels in the flotation units. To reduce the dimensionality of the dataset, Principal Component Analysis, an unsupervised machine learning method, was applied. The soft sensor model was developed using three machine learning algorithms, namely, Ridge Regression, Multi-Layer Perceptron, and Random Forest. The Random Forest model, created with non-reduced data, demonstrated superior performance, with an R-squared value of 96.5% and a mean absolute error of 0.089. The results suggest that the proposed soft sensor model can accurately predict the silicate content in the iron ore flotation concentrate using machine learning algorithms. Moreover, the study highlights the importance of selecting appropriate algorithms for soft sensor developments in mineral processing plants.

Evaluating the performance of Extreme Learning Machine technique for ore grade estimation

Abuntori Clara Akalanya, Al-Hassan Sulemana, Mireku-Gyimah Daniel, Ziggah Yao Yevenyo

Journal of Sustainable Mining

2021

Vol. 20, iss. 2

56--71

Due to the complex geology of vein deposits and their erratic grade distributions, there is the tendency of overestimating or underestimating the ore grade. These estimated grade results determine the profitability of mining the ore deposit or otherwise. In this study, five Extreme Learning Machine (ELM) variants based on hard limit, sigmoid, triangular basis, sine and radial basis activation functions were applied to predict ore grade. The motive is that the activation function has been identified to play a key role in achieving optimum ELM performance. Therefore, assessing the extent of influence the activation functions will have on the final outputs from the ELM has some scientific value worth investigating. This study therefore applied ELMas ore grade estimator which is yet to be explored in the literature. The obtained results from the five ELM variants were analysed and compared with the state-of-the-art benchmark methods of Backpropagation Neural Network (BPNN) and Ordinary Kriging (OK). The statistical test results revealed that the ELM with sigmoid activation function (ELM-Sigmoid) was the best among all the other investigated methods (ELM-Hard limit, ELM-Triangular basis, ELM-Sine, ELM-Radial Basis, BPNN and OK). This is because the ELM-sigmoid produced the lowest MAE (0.0175), MSE (0.0005) and RMSE (0.0229) with highest R2 (91.93%) and R (95.88%) respectively. It was concluded that ELM-Sigmoid can be used by field practitioners as a reliable alternative ore grade estimation technique.