Optimizing industrial flow measurements in mineral processing: Utilizing radiotracers for enhanced data reliability within Mining 4.0.

As the mining sector undergoes rapid transformation, Industry 4.0 principles — such as data digitalization, process automation, and Big Data Analytics — are crucial for developing intelligent mineral processing plants. These principles advance processes towards an interconnected sequence of steps, each relying on high-quality data. Within this framework, low-uncertainty flowmeter data is vital for accurate metallurgical mass balance determination, efficient process control, and the correct application of advanced analytical tools. However, harsh mining conditions can cause significant deviations in flowmeter readings, necessitating robust data validation methods. This paper introduces the novel application of the radiotracer methodology, which provides certified uncertainties around 1%, to optimize flowmeter data accuracy and align with Mining 4.0 requirements. Three industrial validation examples are presented: Flow meter adjustment in leaching processes, evaluating a NaHS loop piping circuit in a molybdenum flotation plant and validating flow meters to assess the hydraulic behavior of recirculation pumping stations for water balance quantification. On-site validations at the leaching plant revealed that only 36% of the measurements were within the acceptable 5% error margin. Flow assurance was confirmed in the NaHS loop piping circuit as radiotracer velocity data showed no blockages. Deviations in the recirculation pumping stations, ranging from 6.91% to 22.55%, highlighted the need for flowmeter adjustments. These findings underscore the value of radiotracers as a validation method. This paper also provides insights for water and environmental impact assessment, metallurgical mass balance calculations, and process optimization, emphasizing the need to integrate radiotracer methodology within the Mining 4.0 framework.