Figure 39 – Digital twin Workflow (online) First principle -based SX model and residual model run concurrently on live plant inputs; compensation layer produces corrected hybrid outputs with feasibility enforcement. Outputs feed operator insights, recommendations, and alerts in real time. 4. OPERATOR ASSISTANT (OPTIMIZATION AND DECISION SUPPORT LAYER) 4.1 Operator Assistant overview The Operator Assistant constitutes the prescriptive layer of the architecture, transforming hybrid digital‑twin outputs into actionable operating guidance for the SX/EW circuit. While the digital twin provides mechanistic and data‑enhanced predictions of process states, the Operator Assistant evaluates these predictions against operational objectives and constraints, generating real‑time setpoints and ranked recommendations under human supervision. 4.2 Decision Variables and Constraints The optimization framework targets a defined set of manipulable plant levers that significantly affect copper extraction efficiency and iron rejection. These include influent pH regulation, distribution of organic flow across SX stages, adjustments to phase ratios, strip flow allocation, and settler interface targets. All recommended setpoints adhere to constraints informed by equipment and process specifications—such as mixer–settler residence-time requirements, maximum allowable organic and aqueous flow rates, extractant loading limits, permissible pH operating windows, rich-electrolyte purity thresholds, and EW current-efficiency constraints. This ensures that all output remains operationally feasible, safe, and immediately actionable. 4.3 Optimization and Decision Logic The Operator Assistant applies a multi-layered optimization strategy. A predictive control layer (short-horizon MPC) stabilizes key process variables—such as acidity and O/A ratios—by forecasting near-term system evolution and implementing minimal corrective moves. In parallel, a MILP formulation addresses discrete operational decisions, including pH-band selection and redistribution of organic flows across stages, enabling identification of optimal configurations
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