An On-Line Machine Vision Flotation Froth Analysis Platform

Froth flotation is a popular process used for the extraction of certain minerals from ore. The effective automatic control of this process has great financial importance. Utilising machine vision as the measurement component of an automatic flotation control system has several advantages: it is a cost effective solution due to its non-contacting sensors and consequent low maintenance, as well as its low initial setup costs; it yields consistent and accurate parameters; and the measurements it makes are available immediately, thus enabling real-time control and minimising the effects of process disturbances rapidly and efficiently. In addition, machine vision can be used as a research tool for investigating froth flotation, a process which is still not fully understood. This work documents the development of an on-line machine vision flotation froth analysis platform that is in use in the industry as the measurement component of an advanced flotation control system and in the academic world as a powerful research tool. Two additional froth analysis applications, namely an embedded froth mobility sensor for use in the flotation industry and a continuous froth video sampling and analysis research platform, are developed in the course of this work. An investigation into continuous video sampling and analysis of flotation froth is performed for the first time and indicates that this mode of froth image acquisition yields more information than traditional froth imaging methods. Recommendations are made with respect to the practical application of continuous froth video sampling and analysis.