Improving Accuracy of Optical Sorters Using Closed-Loop Control of Material Recirculation

Optical sorting is a key technology for the circular economy and is widely applied in the food, mineral, and recycling industries. Despite its widespread use, one typically resorts to expensive means of adjusting the accuracy, e.g., by reducing the mass flow or changing mechanical or software parameters, which typically requires manual tuning in a lengthy, iterative process. To circumvent these drawbacks, we propose a new layout for optical sorters along with a controller that allows re-feeding of controlled fractions of the sorted mass flows. To this end, we build a dynamic model of the sorter, analyze its static behavior, and show how material recirculation affects the sorting accuracy. Furthermore, we build a model predictive controller (MPC) employing the model and evaluate the closed-loop sorting system using a coupled discrete element–computational fluid dynamics (DEM-CFD) simulation, demonstrating improved accuracy.