Enhancing Crushing Productivity Using the Smith Predictor-Based Control

This article presents an application of the Smith predictor-based control strategy for controlling the feed rate of a primary crushing circuit in an iron ore beneficiation plant, focusing on compensating for system dead time. The methodology includes problem characterization, plant modeling, and application at Vale S.A.’s Fabrica Nova unit, Brazil. The results show a 4.3-minute reduction in the time to reach the feed setpoint and a 9.2% increase in the plant’s productivity, without compromising process safety. The proposed strategy contributes to the process control literature by demonstrating the practical application of the Smith predictor for dead time compensation, providing a replicable alternative for other industrial systems.