Sub-Saharan Platinum Concentrator Automation
A full DCS replacement and flotation control upgrade across a platinum concentrator, delivered without losing a production shift.
report_problem The Challenge
The concentrator was running three islanded control systems of different vintages, with no common historian and no path to the site ERP. Mill motor over-torque trips were frequent and unpredictable, and reagent dosing was titrated manually with significant chemical wastage.
build Our Engineered Solution
We deployed a redundant high-speed DCS with automated mill feed tuning, closed-loop spectral reagent dosing, and an OPC-UA telemetry pipe feeding production data directly into SAP. The cut-over was rehearsed in simulation and executed in a phased 14-day window.
trending_up The Outcome
The plant gained 22% OEE in mineral processing, cut reagent consumption by 24%, and now runs against a single real-time operational picture shared by plant and corporate teams.
- • Frequent unpredicted mill motor over-torque trips
- • Manual reagent titration with high chemical wastage
- • Islanded control islands with zero ERP/MES visibility
- • High-speed load balancing DCS with automated feed tuning
- • Closed-loop spectral reagent dosing reducing consumption 24%
- • Real-time OPC-UA telemetry pipe directly to SAP ERP
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