Experiences and Lessons with Advanced Control Systems for the SAG Mill Control in Minera Los Pelambres Daniel A. Silva*, Luis A. Tapia** *Senior Control Eng., Automation Department, Minera Los Pelambres, Choapa, Chile (4001 Apoquindo Ave., 18th Floor, Santiago, tel.: +56-2-7983609; e-mail: [email protected]).. **Concentrator Operations Superintendent, Minera Esperanza,Antofagasta, Chile …
The paper is illustrated by trend plots taken from a SAG mill in a major gold mine. The paper goes on to explain the practical causes of the instability ranging from inappropriate type 2 control strategies to poor control loop tuning and to inappropriate operator intervention caused by lack of operator training.
The methods on how to manage the changing variables around SAG mills have improved over the years with new instrumentation and Advanced Process Control () systems. Despite these improvements, there is a gap between the available technologies and achieving the …
SAG Mill process control classically maintains the SAG mill volumetric filling within a set operating range. Typically a SAG mill weight measurement, by either bearing pressure transducers or load cells, is used as an inferred measurement of volumetric filling. To maintain volumetric filling within a set operating range the SAG weight setpoint use for process control requires regular review ...
SAG mill control is essentially the stabilisation of mill load (and/or power) and density which can be implemented successfully and very cost-effectively on most modern PLC or DCS platforms. The application of advanced regulatory control is a MIPAC speciality which we have
Control of -SemiAutogenous Grinding(SAG) mill weight is an example of an important process that exhibits many of these aspects. Maintaining the SAG mill weight at the optimum value is critical for achieving maximum grind rate efficiency and mill production (Powell, M.S., van der Westhuizen, A.P., & Mainza, A.N. 2009).
Enhanced mill performance. SAGwise total process control uses specially designed acoustic sensors and proprietary process control software to monitor and respond to critical impacts inside your SAG Mill. Conditions inside your mill are automatically adjusted to minimise liner damage, stabilise and then optimise the operation of a SAG Mill.
SAG mill discharge control is quite involved due to few interactive variables, such as mill discharge sump level, classification hydro-cyclone variables (feed density, flow and pressure) and water feed rate to the sump. Model predictive control (MPC), which is a …
Although the mill weight provides a reasonable and reliable indication of mill loading, it is known to be a challenge to control. Fortunately, the patented BrainWave controller has a unique ability to model SAG mill behavior so that responsive, precise control is possible. BrainWave accounts for changes in mill rotation, recycled pebbles, and ...
However, adjusting the mill speed to the optimal state presents a very challenging problem. In a SAG mill, the speed control system is a nonlinear and strongly coupled multivariable system. The proportional integral (PI) vector control method is used in …
This is excellent for good SAG mill control. There are three major sources of dist urbances that produ ce instability in . the grinding circuit. These are, 1. Coarse ore stock pile feeder trips . 2.
Instead, SAG mill process control systems that aim to maximize SAG mill federate should target operation at the optimal volumetric mill filling for the prevailing feed. Despite the importance of volumetric mill filling, a measurement is not traditionally …
Figure 6 – Example of the control room process trend showing SAG mill feed tonnage (maroon), SAG power (teal) and cyclone overflow percent passing 200 mesh (blue) and percent solids (red) Meadowbank is a remote minesite with a rotating crew which poses specific challenges. To
SAG Mill Success—Start with the Basics. SAG mills are often flexible enough to accomplish the same size reduction provided. by two or three stages of crushing and screening, a rod mill, and some or all of the. work of a ball mill. With units available in …
control are discussed. The ROM SAG mill circuit—a brief description The typical ROM SAG mill circuit is depicted in Figure 1. The circuit is usually closed with either a screen or, more commonly, a cyclone for product size classification. The focus of control can be divided into two parts, viz. the
Associate Professor, Mohsen Yahyaei, who is JKMRC's Advanced Process Prediction and Control (APPCo) Group Leader, said the MFP tool includes mathematical models that predict the wear condition of the mill, the level of mill filling, the filling of the steel grinding media and particle trajectory.
This 17th IFAC Symposium on Control, Optimization and Automation in Mining, Mineral and Metal Processing Vienna, Austria. Aug 31 - Sept 2, 2016 Copy ight © 2016 IFAC 65 Real-Tim Simulation and Control of a SAG Mill F. Guerrero ∗ J. Bouchard ∗∗ E´.
• 28 MW GMD for a 40' SAG mill • 28 MW GMD for 42' SAG mill Whether it is size or an installation at the highest altitude (4600 m.a.s.l.), ABB's GMDs are well positioned to contribute to the building of larger and ever more powerful mills. — Leading the gearless mill drive evolution The ABB gearless mill drive (GMD) is the most powerful ...
Process control challenges and opportunities in mineral processing ... A SAG mill may have 10% steel where a ball mill will typically have 30%. Classification is normally carried out in hydro cyclones with the product feeding either a flotation or …
By combining with SAG discharge and screening on the SAG discharge screens, top size control to the ball-mill circuit feed is maintained while still unloading …
SAG mill control fundamentally means managing the load in the mill by adjusting the feed rate of ore to the mill and/or manipulating the rotational speed of the mill. The best way to measure load is to mount the mill on load cells. The load cells are calibrated to measure the total weight of water, grinding media (balls) and ore in the mill ...
At Ok Tedi, ore type and SAG feed size distribution vary widely and frequently. This makes control of the SAG mills by application of the power/pressure relationship difficult. Power logic has traditionally been conservative due to power spikes associated with rapid size-distribution changes. A new expert system was installed in early 2000. The system incorporates multiple state fuzzy logic to ...
OPTIMAL SAG MILL CONTROL USING VIBRATION & DIGITAL SIGNAL PROCESSING TECHNIQUES ABSTRACT Recent developments in low power wireless and Digital Signal Processing (DSP) technologies have given rise to a new system that can monitor vibrations in real-time on the rotating surface of SAG, AG, and Ball mills.
The control system implemented on the Fimiston SAG mill is a regulatory control system where the various set points and constraints are set by the control room operator and the control system d ...
Figures 8 and 9 on the right show results from a gold plant's SAG mill achieved with MillStar's Segregated Ore Feed Controller combined with the Power Optimiser: • The standard deviation of the mill feed control is greatly reduced. • The cyclone feed is more stable, allowing for consistent size separation and feed to downstream processes.
445 PAPER 28 Evolution of SAG Mill Process Control at the Xstrata Nickel Raglan Operation Erik Bartsch1, Chief Engineer Guy Comeau2, Senior Metallurgist Colin Hardie3, Former Chief Metallurgist 1 Process Control Group, Xstrata Process Support 6 Edison Rd, Falconbridge, Ontario
The SAG mill design is based on Outotec's proprietary grinding mill technology, developed over decades for maximum reliability and performance. The mill will be operated as a single stage SAG mill (primary and secondary duty combined) with very high throughput made possible by the use of Outotec's patented Turbo Pulp Lifter (TPL(TM)) Technology.
In general, the SAG mill manufacturers will control the addition amount of medium such as steel ball at 2-8%, so that the capacity of semi SAG mill to process materials can …
Founded by Dr. Karl Gugel, Digital Control Lab started its life in 1998 as an electronics consulting firm known as DiCon Labs. During the early years, DiCon Lab was contacted by a leading cement manufacturer to replace microphone based systems for real-time mill loading measurements. The result was the first generation of MillScan products.
An industrial example of its use is for the problem of SAG mill feed rate control, shown in Figure 12, which is notoriously difficult for a PID controller due to the …
1. The SAG mill speed (rpm) 2. The SAG mill power (MW) 3. The SAG mill feed rate (tph) 4. The SAG mill weight (tonnes) Figure 10. The performance of Train 1 SAG Mill - before the new Manta Cube. It can be seen from this set of operational data that the mill weight varies over a wide range and this is consistent with normal operator control of a ...
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