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In mineral processing plants, grinding is a crucial step, accounting for approximately 50 percent of the total mineral processing costs. Semi-autogenous grinding mills are extensively employed in the grinding circuit of mineral processing plants. Maximizing SAG mill throughput is of significant importance considering its profound financial outcomes. However, the optimum process parameter setting aimed at achieving maximum mill throughput remains an uninvestigated domain in prior research. This study introduces a hybrid intelligent framework leveraging expert knowledge, machine learning techniques, and evolutionary algorithms to address this research need. In this study, we utilize an extensive industrial dataset comprising 36743 records and select relevant features based on the insights of industry experts. Following the removal of erroneous data, a comprehensive evaluation of 17 diverse machine learning models is undertaken to identify the most accurate predictive model. To improve the model performance, feature selection and outlier detection are executed. The resultant optimal model, trained with refined features, serves as the objective function within three distinct evolutionary algorithms. These algorithms are employed to identify parameter configurations that maximize SAG mill throughput while adhering to the working limits of input parameters as constraints. Notably, our analysis revealed that CatBoost, as an ensemble model, stands out as the most accurate predictor. Furthermore, differential evolution emerges as the preferred optimization algorithm, exhibiting superior performance in both achieving the highest mill throughput predictions and ensuring robustness in predictions, surpassing alternative methods.

Semi-autogenous grinding (SAG) mills play a pivotal role in the grinding circuit of mineral processing plants. Accurate prediction of SAG mill throughput as a crucial performance metric is of utmost importance. The potential of applying genetic programming (GP) for this purpose has yet to be thoroughly investigated. This study introduces an enhanced GP approach entitled multi-equation GP (MEGP) for more accurate prediction of SAG mill throughput. In the new proposed method multiple equations, each accurately predicting mill throughput for specific clusters of training data are extracted. These equations are then employed to predict mill throughput for test data using various approaches. To assess the effect of distance measures, four different distance measures are employed in MEGP method. Comparative analysis reveals that the best MEGP approach achieves an average improvement of 10.74% in prediction accuracy compared with standard GP. In this approach, all extracted equations are utilized and both the number of data points in each data cluster and the distance to clusters are incorporated for calculating the final prediction. Further investigation of distance measures indicates that among four different metrics employed including Euclidean, Manhattan, Chebyshev, and Cosine distance, the Euclidean distance measure yields the most accurate results for the majority of data splits.