Semi-autogenous grinding (SAG) mills are commonly used to grind ore into smaller pieces. These mills use a combination of ore and steel balls within the mill to break down the ore.
Impacts generated by the steel balls within the SAG mill can lead to various issues. These impacts can cause the balls to break. Moreover, the repeated impacts on the mill’s liners can wear them down, leading to liner damage or failure. Critical failures of liners might result in mineral leaks.
Common challenges in SAG mill operations:
Serious events like critical failures or significant wear in the SAG mill components often necessitate immediate halting of the process for repairs or part replacements. Moreover, scheduled maintenance to monitor wear and conduct necessary repairs involves stopping production, impacting operational continuity.
These unwanted events increase costs, affect assets, and negatively impact mill productivity.
The sound emitted during the operation of a mill is indeed a valuable source of information. These acoustic signals carry a wealth of data about the mill’s condition, the interactions of its components, and potential irregularities or inefficiencies in the grinding process. By analyzing these sounds, it’s possible to glean insights into the health and performance of the mill without directly interfering with its operation.
ImpactFinder® is a sophisticated system monitors operational conditions by analyzing the acoustic signals generated within SAG and ball mills during operation.
Placing two (or four) industrial microphones in specific positions on the equipment to capture sounds. By employing statistical processing methods to analyze the collected sounds, the system can extract valuable information and characteristics related to the grinding process variables.
The impacts between balls and ore within the mill should be the primary interactions. When the sound analysis suggests impacts between balls and the cylinder liner instead, it typically signifies an issue in the mill’s operation or configuration. This unintended interaction can indicate various problems.
By monitoring the acoustic signals and establishing thresholds, the ImpactFinder® system provides real-time alerts when critical impacts are detected. These alerts can trigger pre-defined operational control rules that help in taking immediate corrective actions or adjustments to prevent further damage or inefficiencies in the milling process.
Customizing the control philosophy for each site’s specific conditions and equipment is crucial. The adaptability to individual parameters like equipment size, mineral characteristics, and overall operating conditions allows for a tailored approach.
ME Elecmetal has plans in progress to expand ImpactFinder implementations, demonstrating our commitment to providing advanced solutions and optimizing mill operations. This expansion will solidify ME Elecmetal’s position as a leader in offering cutting-edge technology for mill optimization and enhancing operational performance in large-scale mining operations.
The key difference of ImpactFinder® with respect to its competitors is it is able to differentiate between critical impacts (steel – steel) and standards (steel – mineral), allowing for more refined control strategies. It’s a crucial aspect in preventing unnecessary wear and tear on the mill components while maximizing the efficient processing of the minerals.
Real-time measurement and adjustment of the mill’s internal load are crucial for maintaining optimal operational efficiency. Being able to prevent overload due to variations in mineral characteristics is a significant advantage. It ensures stability in the milling process, even when there are changes in the size or hardness of the minerals being processed.
Having precise indicators and real-time data from ImpactFinder is instrumental in making informed decisions promptly. It empowers operators to adjust the mill’s parameters, ensuring that the load remains optimal for the milling process.
ImpactFinder® relies on analytical models that necessitate an online connection to various sources of process variables, like the PI system, DCS, or similar platforms, illustrated in the diagram below:
Ariel Medina, Director of ME Digital Lab.
The initial ImpactFinder installations took place at Minera Escondida in 2017 and 2018. By 2022, the intelligent ImpactFinder system had been effectively integrated as an operational control and diagnostic tool in significant mining grinding processes. Notable implementations occurred at Minera Doña Inés de Collahuasi, Minera Los Pelambres, Spence-SGO, and Codelco Andina, showcasing its successful adoption across these sites.
Near-term plans include the implementation of ImpactFinder in an additional eight large-scale mining operations across Chile, Peru, Ecuador, and Panama.
ImpactFinder is a solution originally developed by ECN AUTOMATION, further adapted by ME Elecmetal. This adaptation aims to streamline the implementation process, requiring minimal intervention for assembly and maintenance. Moreover, it maximizes system availability by enabling features such as redundancy or microphone replacement without halting the mill’s operation.
ME Digital Lab engages in multiple technological initiatives to develop solutions, collaborating with top experts in each niche. This strategic partnership ensures the highest quality and expedited time-to-market for our innovations.
