- Deliver consistent, high-quality production to support decarbonization goal to produce “green zinc” using 100% renewable energy by 2040
- Throughput: Sustained 3% increase, boosting zinc output and economic benefit
- Uptime: Over 95% operational uptime, reflecting strong operator engagement
- Stability: More consistent roasting and improved product quality. Reduced variability for ongoing circuits
- Scalability: Sets a precedent for automation across Korea Zinc
- Team Engagement: Collaboration and positive operator feedback
Sun Metals’ automation initiative reflects Sun Metals Group’s focus on operational excellence, sustainability, and digital transformation. Both organisations highlight automation and digitalization as central to competitiveness and future growth.
Sun Metals invests in process optimization and digital platforms to boost reliability, cut costs, and support decarbonization- goals echoed in the company’s mission to be the safest and most competitive zinc refinery.
Deploying PavilionX Model Predictive Control (MPC) at Sun Metals demonstrates these strategic aims. Automating feed rate adjustments and stabilizing production improves efficiency and sets a precedent for scalable automation across the company. This supports Sun Metals’ ambition to produce “green zinc” using 100% renewable energy by 2040.
Challenge
How could Sun Metals stabilize roasting production while improving throughput and quality?
Sun Metals needed to stabilize and improve roasting production.
As Chris Doble, Roasting Superintendent, explained, even a small production increase while maintaining quality is impactful, given the 480,000 tons of zinc concentrate processed each year.
Feed comes from various mines with differing impurities and moisture, plus zinc dross from casting, making consistency difficult. Operators must constantly adjust feed rates to maintain output, and performance varies.
A solution was needed to deliver consistent, high-quality production and address both process complexity and human factors.
Solution
How did PavilionX MPC improve real-time control, operator adoption, and production stability?
To tackle these challenges, Sun Metals and Rockwell Automation launched a collaborative project, deploying PavilionX MPC - a closed-loop automation platform optimizing processes in real time. MPC continuously analyzes variables like oxygen pressure, roaster temperatures and product specifications, dynamically adjusting feed rates, reducing manual intervention.
Rockwell engineers worked closely with Sun Metals operators to configure and refine the system, ensuring it fits operational needs. Training and engagement fostered strong adoption.
Operators report that the MPC system is intuitive, stabilizes production, and empowers them, with over 95% uptime reflecting effective use.
Key benefits include real-time optimization, a sustained throughput increase and support for safety and sustainability goals.
How was PavilionX MPC implemented to support adoption and continuous improvement?
Implementation was collaborative and phased. Planning sessions mapped process challenges, and the MPC system was integrated into existing controls for both roasters. Data was collected in step testing and accurate models of the process interaction were built. Testing and operator feedback ensured the solution was practical and intuitive, with training supporting adoption.
After commissioning, performance was monitored, quickly showing an over 3% throughput increase and over 95% uptime. Monthly review cycles with Rockwell Automation support ongoing optimization and continuous improvement.
Result
What business impact did PavilionX MPC deliver beyond the roasting process?
The project’s benefits extend beyond operations. Increased throughput and uptime unlock significant economic value, strengthening Sun Metals’ reputation as a reliable supplier. Operators are empowered by advanced automation, and the project sets a benchmark for scalable automation and supports sustainability goals, including the pursuit of “green zinc”.
How can Model Predictive Control support operational excellence and sustainability?
For mining and metals companies, even small improvements in throughput, uptime, and process stability can create significant operational and economic value. Complex feed variability, changing production conditions, and operator-dependent decision-making make consistent performance difficult to sustain without model predictive control.
The Sun Metals case demonstrates how Model Predictive Control can help stabilize complex continuous processes, reduce manual intervention, improve operator confidence, and create a scalable foundation for digital transformation. It also shows how operational excellence and sustainability can advance together when automation is applied to improve efficiency, reliability, and resource performance.
Published May 18, 2026
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