Creating a digital twin of the air saturation section in a pressure flotation plant used to clean run-off water in coal pit mines

P.P. Ivanov, S.G. Pachkin, L.A. Ivanova, A.G. Semenov, E.S. Mikhailova
Kemerovo State University, Kemerovo, Russian Federation
Russian Mining Industry №3/ 2026 p. 130-136

Abstract: This paper analyses a process flow diagram of a pressure flotation plant. The analysis showed that the efficiency of pressure flotation is determined by the air saturation of the run-off water, which in turn depends on the pressure during the saturation process. Based on the material balance equations, and with account of the adopted assumptions, a mathematical model of the examined section was obtained in operator form, which made it possible to determine the relationship between the main input and output variables, identify control and disturbance effects, as well as to structure the interdependence of the pressure control and the level in the saturation tank. A digital twin of the studied section was created using Simulink tools within the MATLAB environment based on the developed model, and computational experiments were carried out, resulting in determination of the transient characteristics for the main and cross-control channels. The transfer functions, transfer coefficients, response and delay times have been determined, to quantitatively describe the effect of the control valve positions on the pressure and level in the saturation tank. The system has been identified as static, and the presence of direct and inverse interconnections between the channels has been established. The mathematical relationships and simulation results presented form the basis for the subsequent structural and parametric synthesis of autonomous control systems, including the calculation of compensators and tuning of the PID controllers. The data obtained will improve the accuracy of predicting the dynamics of the air saturation process in the run-off water and can be used in designing efficient control systems for pressure flotation plants in coal mining operations.

Keywords: in-pit run-off water, digital twin, modelling of a control object, automatic control system, pressure flotation, flotation plant, air saturation

Acknowledgements: The research was carried out as part of the ‘Development and implementation of complex technologies in the areas of exploration and extraction of minerals, industrial safety, bioremediation, creation of new deep conversion products from coal raw materials while consistently reducing the environmental impact and risks to human life’ Integrated Scientific and Technical Programme of the Full Innovation Cycle, approved by Order No.1144р of the Government of the Russian Federation dated May 11, 2022, with financial support by the Ministry of Science and Higher Education of Russian Federation, Agreement No.075-15–2022-1201 as of September 30, 2022.

For citation: Ivanov P.P., Pachkin S.G., Ivanova L.A., Semenov A.G., Mikhailova E.S. Creating a digital twin of the air saturation section in a pressure flotation plant used to clean run-off water in coal pit mines. Russian Mining Industry. 2026;(3):130–136. https://doi.org/10.30686/1609-9192-2026-3-130-136

Article info

Received: 15.02.2026

Revised: 24.03.2026

Accepted: 30.03.2026

Information about the authors

Pavel P. Ivanov – Cand. Sci. (Eng.), Associate Professor, Department of Mechatronics and Automation of Technological Systems, Kemerovo State University, Kemerovo, Russian Federation; https://orcid.org/0000-0002-8086-3273; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Sergei G. Pachkin – Cand. Sci. (Eng.), Associate Professor, Department of Mechatronics and Automation of Technological Systems, Kemerovo State University, Kemerovo, Russian Federation; https://orcid.org/0000-0001-9530-3829; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Ludmila A. Ivanova – Cand. Sci. (Eng.), Associate Professor, Department of Technosphere Safety, Kemerovo State University, Kemerovo, Russian Federation; https://orcid.org/0000-0002-4103-8780; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Andrey G. Semenov – Dr. Sci. (Eng.), Professor, Department of General Mathematics and Computer Science, Kemerovo State University, Kemerovo, Russian Federation; https://orcid.org/0000-0002-3136-3942; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Ekaterina S. Mikhailova – Cand. Sci. (Chem.), Director, Institute of Nano-, Bio-, Information, Cognitive and Socio-Humanitarian Technologies, Associate Professor, Department of Technosphere Safety, Kemerovo State University, Kemerovo, Russian Federation; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

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