Unlocking Real-Time Grinding Optimization: Insights from Inside the Mill

Nunez E.; Garcia D.; Morales J.; Gugel K. · IMPC 2024 - 31st IMPC-International Mineral Processing Congress (2024)

Resumen

Achieving operational excellence in real-time requires many elements that work together optimally. The fundamental aspects of a successful implementation depend on accurate, precise instrumentation, real-time data collection, data analytics, and an appropriate optimization platform. Additionally, for all of these components to lead to a successful outcome, the final real-time optimization platform needs to be implemented within the site’s own internal process control system (Nunez, 2022). This paper presents practical learnings and best practices for autogenous (AG), semi-autogenous (SAG), and ball mills (BM) grinding. The discussion includes the implementation of advanced instrumentation consisting of vibration sensors attached to the mill shell under rotation. Also discussed is the application of advanced analytics required to create new measurements that accurately represent the real-time grinding activity occurring in the mill. The application of these Advanced Analytics Measurements (AAM) is compared and contrasted with well-known grinding curves to identify and select the operating point for optimal grinding. Specifically, three industry-wide opportunities, liner wear, pegging detection, and Jb/Jc ratios, are discussed, along with supporting real-time mill shell vibration results to obtain new correlations and optimal grinding process operation. These learnings and best practices are not just theoretical, but practical and applicable in your daily operations, empowering you to optimize your grinding processes. Copyright