Program B
Optimising the grinding, flotation and leaching stages
The aim of this program is to maximise concentrate production at the target grade at the lowest possible cost. To do this, we are integrating grinding and flotation to maximise mill feed tonnage within the constraint of recovery in rougher flotation and final concentrate grade.
The key process variable linking grinding and flotation as well as leach circuits is the degree of liberation of the value mineral, a parameter usually measured off-line in geometallurgical programs. We are developing new soft and hard sensors for in-situ measurements of liberation. Leach circuits show variable performance due to variable value and gangue mineralogy and, in cases, variability in reagent consumption.
Research challenge
Real time predictive models in grinding, flotation and leach circuits using the existing sensor suite at site. This will help identify new opportunities for process optimisation, and identify new sensor data feeds that could be incorporated into the models. This may include new vibration sensors to monitor hydrocyclone performance, mill volumetric load, liberation sensing and new robust sensors for acid leach systems.
Partners
Research projects
Stage project B1: grinding circuit
These project are part of Research Group 1 - Comminution.
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Research project 1 (B RP1): Sensing and optimisation of grinding circuits including mill load and product size
This project has been completed.
Kwaku Boateng Owusu
This project is investigating opportunities for sensing and optimisation in grinding circuits for multi-variate optimisation of flotation feed particle size, liberation and mill throughput.
- Student: Kwaku Boateng Owusu
- Principal supervisors: Adjunct A/Prof Max Zanin, Prof William Skinner, Dr Richmond Asamoah
- Research lead: UniSA
- Translation partner: Manta Controls
This project is linked to Translation Projects 7 and 8 (B TP7, B TP8).
View the YouTube video on ‘Sensing and optimisation of grinding circuits including mill load and product size’
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Research project 2 (B RP2): Predictive machine health monitoring for SAG/AG mills
This project has been completed.
This new technique will enable operators to select appropriate feed rates of processing equipment, thereby providing optimal throughput and prevent the clogging of processing equipment that causes downtime. It will also save energy without over grinding, which causes machine wear and tear.
- Student: Honours students
- Principle supervisor: Dr Lei Chen
- Postdoctoral fellow: Dr Difan Tang
- Research lead: University of Adelaide
- Translation partners: Manta Controls
View the YouTube video on ‘Predictive machine health monitoring for SAG/AG mills'
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Research project 3 (B RP3): New sensor development for particle size in hydrocyclones
Dr Difan Tang
This new technique will enable operators to provide optimal size of particles with adequate liberation matching the downstream pulp chemical conditions and flotation response.
This project is selected for commercialisation.
- Postdoctoral Fellow: Dr Difan Tang
- Principle supervisors: Dr Lei Chen
- Research lead: University of Adelaide
- Translation partners: Manta Controls
This project is linked to Translation Project 8 (B TP8).
View the YouTube video of Dr Difan Tang’s presentation on ‘New sensor development for particle size in hydrocyclones’
Stage project B2: floating circuit
These project are part of Research Group 2 - Flotation
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Research project 4 (B RP4): Sensing and optimisation of flotation circuits and integration with grinding
This project has been completed.
Bismark Amankwaa Kyeremeh
This project is investigating opportunities for sensing and optimisation in flotation circuits for multi-variate optimisation of grade and recovery with focus on PSD and liberation from grinding circuit, froth vision analysis.
- Student: Bismark Amankwaa Kyeremeh
- Principal supervisors: Adjunct A/Prof Max Zanin, Prof William Skinner, Dr Richmond Asamoah
- Research lead: UniSA
- Translation partners: Manta Controls, Magotteaux
This project is linked to Translation Projects 8 and 9 (B TP8, B TP9).
View the YouTube video of Bismark Amankwaa-Kyeremeh’s presentation on ‘Sensing and optimisation of flotation circuits and integration with grinding’
Stage project B3: tails leach circuit
These project are part of Research Group 3 - Leaching
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Research project 5 (B RP5): Metal organic framework based fibre-optic sensors
This project has been completed.
Linda Rozenberga
This project is evaluating in-situ and ex-situ probes and analytical techniques with a focus on free acid, Fe (III)/ Fe (II), and Silica in solution and their correlation to Uranium recovery and acid consumption in tails leach circuits for different feed types.
- Student: Linda Rozenberga
- Principal supervisors: Prof David Beattie, Prof Marta Krasowska, Prof William Skinner
- Postdoctoral fellow: Dr Richmond Asamoah
- Research lead: UniSA
- Translation partners: Magotteaux
This project is linked to Research Project 6 (B RP6) and Translation Project 10 (B TP10).
View the YouTube video of Linda Rozenberga’s presentation on ‘Metal organic framework based fibre-optic sensors’
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Research project 6 (B RP6): Diffusive processes in mineral processing
This project has been completed.
Kirsten Louw
This project aims to model diffusion of Fe3+ ions in MOF and solve non-linear diffusion equation with application to population dynamics. The governing equation will be solved using symmetry analysis.
- Student: Kirsten Louw
- Principal supervisors: A/Prof Bronwyn Hajek, Prof William Skinner
- Postdoctoral fellow: Dr Richmond Asamoah
- Research lead: UniSA
- Translation partners: Magotteaux
This project is linked to Research Project 5 (B RP5).
View the YouTube video of Kirsten Louw’s presentation on ‘Diffusive processes in mineral processing’
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Research project 7 (B RP7): Formation of MIP particle film on substrate and successful detection of flotation frothers via gravimetric detection
This project has been completed.
Dr Todd Gillam
This project will develop thin films for chemical tracking during flotation. Specifically, collector and frother sensors will be developed.
- Postdoctoral Fellow: Dr Todd Gillam
- Principal Supervisors: Prof Marta Krasowska, Prof David Beattie, Prof William Skinner, A/Prof Anton Blencowe
- Research lead: UniSA
- Translation Partner: Magotteaux
View the YouTube video of Dr Todd Gillam’s presentation on ‘Formation of MIP particle film on substrate and successful detection of flotation frothers via gravimetric detection’
Translation projects
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Translation project 7 (B TP7): Manta Mic Acouster Analyser
This project has been completed.
Dr Richmond Asamoah
This translation project supports Research Project 1 (B RP1) towards sensing and optimisation of grinding circuit through acoustic sensor response to ore complexity and variability.
- Chief Investigators: Adjunct A/Prof Max Zanin, Prof William Skinner
- Postdoctoral Fellows: Dr Richmond Asamoah
- Translation Partners: Manta Controls, Magotteaux
View the YouTube video of Dr Richmond Asamoah’s presentation on ‘Manta Mic Acouster Analyse’
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Translation project 8 (B TP8): Ultrasonic PSD sensors
This project has been completed.
This translation project supports B TP1, B TP3 and B TP4 towards sensing and optimisation of both grinding and flotation circuit through on-line PSD measurements using ultrasonic PSD sensors.
- Chief Investigators: Adjunct A/Prof Max Zanin, Prof William Skinner
- Postdoctoral Fellows: Dr Richmond Asamoah
- Translation Partners: Manta Controls, Magotteaux
View the YouTube video of Dr Richmond Asamoah’s presentation on ‘Ultrasonic PSD sensor’s
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Translation project 9 (B TP9): Pulp Chemistry Monitor for improved predictive flotation model and process performance
Dr Richmond Asamoah
This translation project seeks to install the Pulp Chemistry Monitor, first at the rougher cells, and incorporate the data collected into a predictive flotation model for better flotation performance. The translation project also supports Research Project 4 (B RP4) towards sensing and optimisation of flotation circuit through pulp chemistry response and sensitivity to ore variability and complexity.
This project is selected for commercialisation.
- Principal supervisors: Dr Richmond Asamoah, Adjunct A/Prof Max Zanin, Prof William Skinner
- Postdoctoral Fellows: tbc
- Translation Partners: Manta Controls, Magotteaux
View the YouTube video of Dr Richmond Asamoah’s presentation on ‘Pulp Chemistry Monitor for improved predictive flotation model and process performance’
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Translation project 10 (B TP10): Tails Leach Circuit
This project has been completed.
The aim of this translation project is to perform detailed laboratory experiments with the new sensors developed under conditions similar to the tails leach circuit of BHP Olympic Dam. This translation project supports Research Project 5 and 6. (B RP5 and B RP6).
- Chief Investigators: Prof David Beattie, Prof William Skinner
- Postdoctoral Fellows: Dr Richmond Asamoah
- Translation Partners: Magotteaux, Rockwell Automation
View the YouTube video of Dr Richmond Asamoah’s presentation on ‘Tails Leach Circuit’
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Translation project 11 (B TP11): Development of laboratory AG/SAG mill
This project has been completed.
Dr Richmond Asamoah
The aim of this translation project is to design and fabricate a laboratory AG/SAG mill for batch scale experiments. This translation project will support Research Project 1 (B RP1).
- Chief Investigator: Prof William Skinner
- Postdoctoral Fellow: Dr Richmond Asamoah
- Translation Partner: Magotteaux
View the YouTube video of Dr Richmond Asamoah’s presentation on ‘Development of laboratory AG/SAG mill’