Model-based supervision of valves in a flotation process

An observer based approach for detecting clogging in valves in flotation processes is investigated. Integral action and linear feedback applied to a nonlinear process model constitutes the observer for which local stability is shown. The integral terms give estimates of the clogging in the valves of the process and this estimate is compared to a constant threshold. Experiments on real data from Boliden´s flotation series at the Boliden Area Concentrator, Sweden, show no false alarm during any of the two working conditions, PI control and LQ control. It is also shown that cloggings, simulated by manipulating measurement data, are promptly detected. The observer based fault detection algorithm is compared to an algorithm based on parameter estimation and advantages of the two approaches are highlighted.