Boost metal recovery and process efficiency with advanced process control, condition monitoring and instrumentation to optimize flotation, thickening, milling, and grinding circuits.
Grinding and milling circuits are energy and capital intensive in the entire mining operation. Keeping SAG and Ball mills and high pressure grinding rolls online and running optimally is critical to flotation efficiency and maximizing metal recovery. However, these circuits experience variations in particle size, feed rate and moisture content, which can lead to plugging, high vibration and machine bearing wear, and ultimately unplanned downtime and labor-intensive restarts.
Emerson can help you achieve higher availability in SAG and ball mills and high pressure grinding rolls with advanced condition monitoring solutions to detect issues early. Emerson’s advanced process control solutions can help optimize your grinding and milling circuits and achieve a more consistent grind while reducing energy consumption.
SAG/Ball Mill Monitoring
Real-time mill condition monitoring to improve your mill’s uptime.
SAG/Ball Mill Wireless Measurement Solutions
Improve mill availability and uptime to optimize your grinding circuit.
Clarkson knife gate valves
Optimize grinding circuit performance and improve mill uptime with Stalwart isolation valve solutions.
DeltaV DCS for advanced SAG/Ball mill control
Advanced process control solutions to increase SAG and ball mill throughput.
Classification equipment like hydrocyclones and vibrating screens play an important role in the overall performance of the grinding and crushing circuit. Ore misclassification impacts downstream mineral processing leading to increased regrinding, decreased flotation efficiency, higher energy consumption and lower metal recovery. The fundamental problem with operating hydrocyclones and vibrating screens is that they are very sensitive to process changes yet are poorly instrumented. Thus, hydrocyclone monitoring is reliant on visual inspection.
With Emerson’s advanced condition monitoring solutions, you can detect problems like roping and plugging in your hydrocyclones, various emerging problems with your vibrating screens and optimize overall grinding circuit performance.
Clarkson knife gate valves
Improve hydrocyclone performance with stalwart isolation valve solutions.
Hydrocyclone Monitoring
Real-time performance monitoring of your hydrocyclone to optimize grinding circuit performance.
DeltaV for mining and minerals applications
Equip your operators with insight and control to achieve operational excellence.
Optimizing flotation circuits and thickener operations can be complex to achieve due to variability with incoming ore. Performance is dependent on several process variables and minor process disturbance can impact metal recovery and increase reagent use. In addition, flotation and thickener circuits are subject to unplanned downtime due to failure of critical pumps, motors and other associated mechanical equipment.
Emerson’s automation and advanced process control solutions can help you improve process stabilization and optimize flotation and thickener operation. Valve solutions help improve slurry flow management and improve flotation efficiency. Wireless condition monitoring solutions can help minimize unplanned downtime by predicting mechanical failure.
DeltaV DCS for advanced flotation cell and thickener control
DeltaV DCS for advanced process control for improved flotation and thickener efficiency.
Clarkson knife gate valves
Stalwart isolation valve solutions for optimized thickener performance.
Your ability to maximize ore recovery, process efficiency and throughput starts with your facilities' stockpile and feed. Given variability in ore hardness and size, you need as much clarity as possible to achieve optimum mineral liberation.
With Emerson's expert measurement solutions, you can gain the insight necessary to configure your process for repeated success. In addition to supplying advanced process inputs, our solutions can also automate the collection of stockpile levels and equipment condition. With these actionable insights, you staff will consistently perform to your expectations.
Solids level measurement solutions
Accurate and cost effective solids measurement with minimum maintenance and easy installation.
Asset performance management solutions
Condition monitoring and improved asset performance management of your critical fixed and mobile mining assets.
DeltaV for mining and minerals applications
Equip your operators with insight and control to achieve operational excellence.
David Harrach
In a North American Mining article, Optimizing all the variables related to comminution and separation requires sophisticated control strategies, Emerson’s David Harrach teamed with Devin Marshman from Emerson Impact Partner, Spartan Controls.
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Todd Walden
Artificial intelligence (AI) and machine learning (ML) are rapidly changing the way organizations leverage analytics. These systems enable complex analysis that human beings simply cannot perform manually, making it possible to solve difficult problems and identify actionable strategies to improve production, efficiency, sustainability, and safety. Undergirding this analytics solution is a...
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Jim Cahill
This hydrocyclone separation control and optimization application addresses the problems associated with roping, plugging, and undesired particle classification. It characterizes the different operating parameters of each cyclone. Having this information per cyclone allows the execution of efficient control strategies.
read moreFAQs About Automation and Control of Grinding, Milling and Flotation
Miners can achieve improved uptime by deploying condition monitoring solutions for SAG/Ball mills and high-pressure grinding rolls.
Miners can increase their throughput and efficiency by applying advanced process control in their grinding circuits.
Integrated quadratic control (IQC) is a newer method of closed-loop control, and its use is growing rapidly for ore processing applications. IQC can be applied in many processes, but has been particularly beneficial in flotation optimization.
Integrated quadratic control (IQC) is a newer method of closed-loop control, and its use is growing rapidly for ore processing applications. IQC can be applied in many processes, but perhaps the greatest sustainability benefit occurs when it is used to improve operation of SAG mills as these typically consume considerable amounts of energy.
