The results of the process control improvement project aimed at improving the quality of Australian Bulk Minerals' (ABM) iron ore pellets produced by four vertical shaft furnaces are very positive. These results are achieved through process stabilisation and optimisation, improvement in process monitoring and taking early corrective actions when operating variables were outside the target ranges._x000D_
A number of benefits are obtained from this project. These benefits include: More consistent and improved pellet quality. The average cold compression strength (CCS) value of pellets produced during the eight-month trial is 260 kg/pellet, which is 16 kg/pellet higher than that produced during the 12 months prior to the trial (244 kg/pellet)._x000D_
Reduction in the heat input by eight per cent, from 727 MJ/tonne to 668 MJ/tonne._x000D_
Reduction in bentonite rate by six per cent, from 7.1 kg/tonne to 6.7 kg/tonne._x000D_
Increase in the furnace throughput rate by four per cent and additional production of 10 000 tonnes per annum through process stabilisation._x000D_
Better understanding of the process behaviour. This knowledge is valuable not only for setting the target operating conditions but also for developing the ABM expert system to control the process.