Thickening & tailings management
AI-controlled thickener underflow density, flocculant dosing, rake torque, and bed depth — plus water recovery planning across the tailings circuit to protect dam integrity and cut fresh-water draw.
概要
Tailings has moved from an afterthought to a board-level risk. Brumadinho and other failures shifted regulator posture permanently. Meanwhile water is a production constraint in most major orebodies, and every ton of tailings carries residual chemistry.
Conventional thickener control leaves money on every rake revolution: flocculant is over-dosed to protect against upset; underflow density is kept conservative to avoid rake torque spikes; supernatant clarity is compromised when feed rate shifts.
BrainiAll AI Autopilot ties the whole tailings circuit together — thickener bed level, rake torque, underflow pump speed, flocculant flow, and overflow turbidity — and holds it in the sweet spot. Water recovery climbs, flocculant drops, and the dam receives paste at a more predictable density.
Autopilotの機能
連続的・多変数制御 — 単一ループPIDではありません。アドバイザリ層アーキテクチャにより安全性はそのまま維持されます。
Flocculant dose optimization
Cuts over-dosing by 10-25% while keeping overflow clarity within spec.
Rake torque protection
Predictive torque control prevents rake-locking events and unplanned lifts.
Underflow density maximization
Pushes solids % to target while keeping torque and clarity in safe envelope.
Water-balance forecasting
Coordinates reclaim pumping with plant demand to minimize make-up water draw.
Dam deposition planning
AI forecasts daily tons to deposit and flags compliance risks before they happen.
継続的に調整される変数
AIはサークルのすべてのセンサーを読み、最適なセットポイント組み合わせをリアルタイムで解決します。
- Flocculant flow (g/t)Primary reagent lever.
- Underflow density (% solids)Target vs rake torque safety.
- Bed depth (m)Controls residence time and clarity.
- Rake torque (kNm)Safety-critical metric monitored in real time.
- Overflow turbidity (NTU)Quality of recovered water.
On a 50 Mt/y tailings stream, a 15% flocculant reduction can translate to several million dollars per year in reagent savings, plus major upside from fresh-water avoidance. Beyond cash: audit-ready logs and explainability materially reduce regulatory and reputational risk.
