Abstract
This study presents a sustainable and adaptive approach to mineral processing. A hybrid intelligent control system was developed to beneficiate fine chromite ore in a jigging machine. The objective is to enhance separation efficiency and reduce chromium losses through real-time optimization of process parameters under variable feed conditions. The method addresses ore composition fluctuations by integrating three components: Physical modeling of particle motion, regression analysis, and neural network-based prediction. The jig bed level and pulsation frequency are used as control variables, while the Cr2O3 content in the feed (Cr) is treated as a disturbance. A neural network predicts the Cr2O3 content in the concentrate (Cc) and in the tailings (Ct), representing chromite-rich and gangue fractions, respectively. The optimization is performed using a constrained Interior-Point algorithm. The model demonstrates high predictive accuracy, with a mean squared error (MSE) below 0.01. The proposed control algorithm reduces chromium losses in tailings from 7.5% to 5.5%, while improving concentrate quality by 3–6%. A real-time human–machine interface (HMI) was developed in SIMATIC WinCC for process visualization and control. The hybrid framework can be adapted to other mineral processing systems by adjusting the model structure and retraining the neural network on new ore datasets.