861
Digitalizing Conveyed Process Feed Flows for Improved
Ore Quality and Process Control
Henry Kurth
Scantech International Pty Ltd
ABSTRACT: Process operators can control the quality of plant feed by measuring conveyed flows after
primary crushing to digitalize quality parameters that affect processing. Measurements of multi-elemental
content, moisture level and fragmentation are used to optimize process performance. Ore quality is increased by
removing waste parcels and blending improves quality consistency. Mill feed rate, reagent dosing, and materials
handling are controlled based on these real time measurements. Technologies such as Prompt Gamma Neutron
Activation Analysis (PGNAA) for representative, continuous multi-elemental analysis, microwave transmission
for continuous free moisture measurement, and 3D Infrared camera based particle size distribution analysis
have all proven beneficial.
INTRODUCTION
A digitalization strategy utilizes digital technologies to
create opportunities for increased efficiency and revenue.
Many operations in the minerals sector lack sufficient data
at key points in the material flow processes to effectively
manage individual processes. The resulting inefficien-
cies lead to significant underperformance across the busi-
ness unit. Measurement of many equipment performance
parameters, such as the many sensors on haul trucks, is well
advanced and broadly adopted, but few sensors focused on
ore quality have been implemented.
A, if not the, primary purpose of a mining operation
is to extract as much product as effectively, efficiently, and
safely as possible from an orebody and achieve acceptable
overall operational sustainability. It is not unreasonable to
expect that there would be a detailed knowledge of mined
material quality to be processed to allow optimization of
process performance. In reality, real time representative
measurement of ore quality between the mine and mill is
the exception rather than the rule as few sites have adopted
proven techniques to benefit from availability of such digi-
tal data. The nature of sensors, the physics principles they
use, and different materials handling processes limits the
opportunity to apply representative measurement to some
bulk material transfer techniques. Conveyed flows have
proven to provide the ideal presentation of mined material
to sensors which provide penetrative and continuous mea-
surement with high precisions and frequency to enable real
time quality control.
The application of high performance sensors provid-
ing representative, real time data measurement of conveyed
flow quality has been slow in adoption in the minerals sec-
tor despite various systems being available and well proven
for some decades with demonstrated short payback peri-
ods. Fragmentation measurement through digital camera
technology has been adopted much more widely than
moisture and composition measurement because fragmen-
tation has proven useful in assisting with comminution
improvements, is directly related to blasting, is relatively
easy to implement and has obvious and immediate ben-
efits. Differences between technologies used for this leads to
Digitalizing Conveyed Process Feed Flows for Improved
Ore Quality and Process Control
Henry Kurth
Scantech International Pty Ltd
ABSTRACT: Process operators can control the quality of plant feed by measuring conveyed flows after
primary crushing to digitalize quality parameters that affect processing. Measurements of multi-elemental
content, moisture level and fragmentation are used to optimize process performance. Ore quality is increased by
removing waste parcels and blending improves quality consistency. Mill feed rate, reagent dosing, and materials
handling are controlled based on these real time measurements. Technologies such as Prompt Gamma Neutron
Activation Analysis (PGNAA) for representative, continuous multi-elemental analysis, microwave transmission
for continuous free moisture measurement, and 3D Infrared camera based particle size distribution analysis
have all proven beneficial.
INTRODUCTION
A digitalization strategy utilizes digital technologies to
create opportunities for increased efficiency and revenue.
Many operations in the minerals sector lack sufficient data
at key points in the material flow processes to effectively
manage individual processes. The resulting inefficien-
cies lead to significant underperformance across the busi-
ness unit. Measurement of many equipment performance
parameters, such as the many sensors on haul trucks, is well
advanced and broadly adopted, but few sensors focused on
ore quality have been implemented.
A, if not the, primary purpose of a mining operation
is to extract as much product as effectively, efficiently, and
safely as possible from an orebody and achieve acceptable
overall operational sustainability. It is not unreasonable to
expect that there would be a detailed knowledge of mined
material quality to be processed to allow optimization of
process performance. In reality, real time representative
measurement of ore quality between the mine and mill is
the exception rather than the rule as few sites have adopted
proven techniques to benefit from availability of such digi-
tal data. The nature of sensors, the physics principles they
use, and different materials handling processes limits the
opportunity to apply representative measurement to some
bulk material transfer techniques. Conveyed flows have
proven to provide the ideal presentation of mined material
to sensors which provide penetrative and continuous mea-
surement with high precisions and frequency to enable real
time quality control.
The application of high performance sensors provid-
ing representative, real time data measurement of conveyed
flow quality has been slow in adoption in the minerals sec-
tor despite various systems being available and well proven
for some decades with demonstrated short payback peri-
ods. Fragmentation measurement through digital camera
technology has been adopted much more widely than
moisture and composition measurement because fragmen-
tation has proven useful in assisting with comminution
improvements, is directly related to blasting, is relatively
easy to implement and has obvious and immediate ben-
efits. Differences between technologies used for this leads to