In an industry where small improvements can yield significant cost savings and productivity gains, mining companies are increasingly turning to automation and data-driven optimisation to stay competitive. ABB’s Advanced Process Control (APC) system, powered by its Expert Optimizer platform, is emerging as a key enabler of smarter, more efficient mining operations.
“Advanced Process Control systems are designed to sit above the plant’s basic control layer,” explains digital solutions sales manager, Kabeer Sewpersad at ABB process automation, process industries. “They act as a layer of intelligence, making small, precise adjustments that optimise performance without disrupting operations.”
What is advanced process control?
In a typical mining setup, day-to-day operations are managed by a DCS or scada system, also known as Level 2 systems. ABB’s APC solution, Expert Optimizer, operates as a Level 3 control system, integrating seamlessly with ABB’s flagship 800xA DCS platform or with third-party systems.
“Expert Optimizer leverages technologies such as Model Predictive Control (MPC) and artificial neural networks to analyse and refine key process parameters in real time,” notes Sewpersad. “It does not make large-scale changes, which is still the domain of the DCS. What it does is introduce subtle, incremental refinements that drive long-term benefits.”
Seamless integration and minimal disruption
A standout feature of ABB’s APC solution is its non-invasive deployment. “If the customer is already using our 800xA DCS, we simply add Expert Optimizer as an additional server. It integrates inherently with 800xA by design,” says Sewpersad. Even when a client uses a third-party DCS, Expert Optimizer remains highly compatible. “It is flexible and system-agnostic, allowing us to implement APC as a standalone layer with minimal disruption,” he adds.
This flexibility is especially valuable in mining, where unplanned downtime can result in significant losses. Since Expert Optimizer operates independently of direct control layers, its deployment does not interfere with production.
Fingerprint assessments for customised implementation
There is no one-size-fits-all approach to APC deployment. ABB begins each engagement with a fingerprint assessment or a tailored questionnaire to understand the existing plant setup, automation readiness for APC and potential areas of improvement.
“We send an engineer on site for a week or two to gather historical data, interview operators and assess whether the plant has the necessary infrastructure, like variable speed drives, for APC to be effective,” says Sewpersad. “This ensures we are proposing solutions that deliver real value.”
With more than 25 years of APC experience, ABB has built a library of industry-specific base models that can be quickly adapted for individual clients. “For example, we already have templates for grinding plants. Customisation then becomes a matter of finetuning rather than starting from scratch,” he adds.
Real, measurable benefits for mining
In the mining sector, the benefits of APC are particularly striking in comminution and grinding processes. Here, APC can deliver up to 2,5% increase in throughput, 4,3% improvement in particle size distribution, 10,9% reduction in specific energy consumption, reduced grinding media consumption, improved downstream stability and reduced variability. “When you tighten control over the grinding process, you are also stabilising what flows into the flotation, thickening and smelting stages. That kind of upstream optimisation has a cascading effect across the entire value chain,” says Sewpersad.
Across multiple stages, cumulative improvements can be substantial: up to 20% improvement in milling efficiency, 15% reduction in losses in cleaner circuits, 4% gains in thickening performance and 3% enhancement in smelter efficiency.
Because Expert Optimizer monitors performance through built-in KPI tracking, clients can see the impact in real time. “Our platform enables customers to measure how well they are using the APC system, track savings shift by shift, and compare actual outcomes with projected gains like energy savings or reduced reagent use,” explains Sewpersad.
A strategic, phased approach
ABB encourages mining clients to implement APC in stages. “Start with one process, realise the return on investment and then use that success to fund further improvements,” advises Sewpersad. “This phased rollout not only reduces risk, but also builds long-term trust and collaboration between ABB and the client.”
With its proven Expert Optimizer platform, seamless integration into the 800xA DCS, and a clear path to measurable operational gains, ABB is helping mining clients unlock a new level of performance, one process at a time. “You will be surprised how even a 1% or 5% change can result in major efficiency gains over time,” concludes Sewpersad.
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