Design of a model predictive controller for interface level regulation in oil sands separation cells

Separation cells used in primary extraction in the oil sands industry are integral components in the overall process of bitumen extraction. Good regulation of the interface level between the bitumen froth and the middlings in these cells can result in a significant improvement in bitumen recovery and heavily influence process economics. This paper details a case study application of identification and the design of a model based predictive controller for the separation cell process. Model predictive control (MPC) using linear models is designed, implemented and tested in real time on the industrial separation cell. The test results show that the MPC scheme provides significant benefits over current operation which uses a PID controller. The benefits include significant reduction in the variance of the interface level and underflow pump movement, resulting in higher bitumen recovery, smoother operations downstream and pump energy savings.