Outotec FrothSenseTM

Consistent information for online process control Traditionally, flotation plant operators have had to depend on visual assessments of froth appearance when making operative decisions. As interpretations between operators can vary greatly from shift to shift, this can lead to inconsistent process results. The Outotec FrothSense
TM

Benefits
Provides consistent information
For use by operators For process control and optimization

Stabilized process
Through the usage of froth properties in process control

system enables the plant to

overcome subjective factors in order to provide consistent information 24 hours a day for use by operators, process control and optimization. The FrothSense system measures several essential properties of froth appearance, including froth speed, direction, bubble size, froth stability and froth color, while also providing statistical data related to these variables. The measured froth properties, together with on-stream analyzer assays, allow the creation of efficient and robust strategies for advanced flotation process control by using a system such as Outotec ACT. In addition, FrothSense delivers live video streams from the froth cameras directly to the control room.

Flexible operation
Fully automatic operation Consistent performance Convenient monitoring Simple installation, operation and maintenance

Outotec FrothSense features

FrothSense is a tool for froth surface analysis providing real-time measurements and statistics of: Froth speed and direction Bubble size distribution Froth stability Froth color (RGB and CIE-LAB) A typical FrothSense installation has several froth imagers mounted on top of flotation machines. The imagers feature an advanced Power over Ethernet (PoE) solution that makes it possible to transmit all data and power for both the camera and the LED lights with just one standard Ethernet cable. The imagers are networked through FrothSense Connection Cabinets to a FrothSense Analysis Server, which runs the necessary machine vision algorithms and acts as an interface to the plant automation network using OPC. In order to fully utilize the real-time froth analyses, the FrothSense system should be accompanied by Outotec ACT Advanced Process Control system. The ACT system makes it straightforward to control the froth speed of the camera-equipped flotation machines, or even to build a comprehensive grade-recovery system for the optimization of the entire flotation circuit. Main advantages of FrothSense are: High-quality digital network cameras Lightweight, allowing easy handling and installation Simple cabling single cable for all data and power for imager and lights Central data analysis in FrothSense Analysis Server In addition to the online analyses of FrothSense, the captured image data can be saved for future inspection. This feature is especially useful in process studies, or if the need arises to develop new algorithms in FrothSense. FrothSense Imager Assembly The FrothSense Imager Assembly consists of a high-resolution color camera, controlled LED lighting and a convenient mounting tube. The imager module is designed for flotation plant environments. FrothSense Connection Cabinet The FrothSense Connection Cabinet provides a central connection point for up to 16 imagers, featuring both
FrothSense camera image, with bubble speed analysis. Individual arrows indicate the speed and direction of the respective regions. FrothSense camera image, with bubble size analysis. Red lines indicate bubble borders and blue areas indicate the bubble highlights. FrothSense camera image, with no analysis data

fiber-optic and copper media connections to the plant network. The system supports virtually any network topology, such as the star or ring configurations. The cabinet is equipped with IP67-rated connectors that eliminate the need for opening the cabinet when connecting cameras. The system is designed for easy maintenance access, having all the power supply units and fuses for the cameras and lights in one convenient place. FrothSense Server The FrothSense server is the heart of the operation as it captures and analyzes the footage delivered by the camera network and publishes the results using an OPC server.

Outotec solution with FrothSense, ACT and Courier for advanced flotation control
Outotec FrothSense

FrothSense Connection Cabinet

Froth speed & characteristics

Slurry Control actions

Outotec Courier Analyzer

Outotec ACT

Outotec FrothSense
Froth Imager Assembly (FIA) Resolution Material Digital image data type Live video stream frame rate IP rating Dimensions Weight Operating temperature range Humidity Power FrothSense Connection Cabinet (FCC) Max. number of imagers per cabinet IP rating Material Cabinet mounting Enclosure dimensions (Width x Depth x Height) Weight Connection between imager (FIA) and cabinet (FCC) Connection between cabinet and server Max. cable length between imager (FIA) and cabinet (FCC) Max. total length between imagers (FIA) and single cabinet (FCC) Power m m mm kg 16 IP66 / NEMA 4X Painted Stainless Steel AISI304 tab (wall mounting) 520x220x600 25 Ethernet CAT6 Ethernet CAT6 or Multimode fiber Wireless (Option) 802.11 ** 100 1000 110 / 230 VAC, 50/60*** Hz, 340 W mm kg C % fps pixels 800x600 Stainless Steel AISI316 ,Plastic, Coated aluminium JPEG, H.264, Motion JPEG 30 IP66 / NEMA4X Diameter max 360, Height 860 9 0-45 5 95 0*

Outotec FrothSense is delivered as an operational package containing: nn Froth Imager Assemblies nn Connection Cabinets nn Analysis server nn Software license Outotec - A lifetime of service Outotec provides services for the entire lifecycle of your asset, from single pieces of equipment to entire plants. Outotec offers services through a global network of service centers that are committed to providing support whenever needed. Outotec services are designed to optimize the

* No external supply needed, powered by FCC ** Option, recommended only with 4 imager units (FIA) or less ***Absolute maximum power. Depends on the number of connected imagers. The technical data is subject to change without notice.

customers plants, equipment and processes. They cover everything from spare parts and maintenance to plant evaluations and upgrades, as well as project management and training.

Outotec develops and provides technology solutions for the sustainable use of Earths natural resources. As the global leader in minerals and metals processing technology, Outotec has developed over decades several breakthrough technologies. The company also offers innovative solutions for the chemical industry, industrial water treatment and the utilization of alternative energy sources. Outotec shares are listed on the NASDAQ OMX Helsinki.

automation@outotec.com www.outotec.com Copyright 2012 Outotec Oyj. All rights reserved.

Finland, March 2012.