EuroСhem introduces digital ore density monitoring system at Usolsky potash plant

EuroChem has launched a machine learning-driven digital sensor system for monitoring ore pulp density at its Usolsky Potash Plant, resulting in a reported economic benefit of 87 million rubles since the start of pilot operations.

Developed jointly by EuroChem specialists and the Digital Technologies and Platforms (DTiP) team, the automated system calculates the density of ore pulp in real time by analyzing data from pumps, pressure sensors and flow meters. The company says the new approach replaces traditional radioisotope densitometers, which involve higher maintenance costs and operational constraints.

Roman Bushmakin, Director of Digitalization at the Usolsky Potash Plant and the project’s initiator, stated that the machine learning algorithm enabled a shift away from physical measurements to a higher level of process control. The algorithm is integrated into the manufacturing execution system (MES) and automatically generates recommendations for operators, allowing them to quickly adjust production settings and minimize deviations.

Currently, the technology is in use in the crushing and thickening sections and is undergoing testing in the flotation stage of processing.

According to Aleksey Trubchenko, Head of the Digitalization Department for Mining Production at EuroChem’s Central Potash Plant, the project aligns with the company’s broader digital transformation strategy, including the adoption of artificial intelligence in critical production processes.