Blending Flow Configuration for Multi-Source Ore Routing
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Solution Overview
Problem
Conventional material processing systems lack the computing infrastructure and logic to efficiently handle and blend materials with diverse properties from multiple sources, particularly in mining operations, leading to inefficiencies in ore processing and increased risks of conveyor overflows.
Innovation Solution
A blending flow configuration and overflow management configuration are implemented in the material processing system, utilizing data from block models, lab assays, and on-stream analyzers to optimize the routing of materials through a conveyance network, assigning materials to grinding lines based on their properties and capabilities, and managing flow to prevent overloads by configuring variable speed routing and blending ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional material processing systems use a single source-to-sink configuration without blending support, then the system design is simple, but the system cannot efficiently handle materials with diverse properties from multiple sources
Solution Approach 1:
The patent implements a universal blending flow configuration that can handle multiple material sources with diverse properties through a unified system architecture. The system uses a common conveyance network that can process different ore types (hard rock, soft rock, mixed ore) from multiple sources and route them to appropriate grinding lines based on material properties, making the system multi-functional rather than dedicated to single material streams
Solution Approach 2:
The patent employs dynamic routing logic that can adaptively adjust material flow paths based on real-time conditions. The system uses variable speed routing and dynamic blending ratios that can change operational parameters on-the-fly to optimize processing of different material types, transitioning from static single-source configuration to dynamic multi-source blending capability
2Productivity
If manual methods are used to optimize material processing system, then the system operation is simple to implement, but the system cannot efficiently minimize conveyor overflows and meet multiple requirements
Solution Approach 1:
The patent implements automated optimization systems that use feedback from material properties data, grinding line performance data, and real-time system state to dynamically adjust routing decisions and blending ratios. The system continuously monitors conveyor loads, material characteristics, and processing line capacities, using this feedback to minimize overflows and optimize throughput automatically rather than relying on manual intervention
Solution Approach 2:
The patent replaces manual optimization methods with automated computing infrastructure and algorithms. The system uses software-based routing logic, automated blending calculations, and computer-controlled conveyance systems to substitute human operators in making real-time optimization decisions, thereby increasing productivity through faster, more accurate automated control
3Productivity
If materials are routed without optimizing for grinding line capabilities, then the routing process is simple, but the downstream processing efficiency is reduced
Solution Approach 1:
The patent applies local quality by matching specific material properties to specific grinding line capabilities. The system analyzes material characteristics (hardness, ore type) and routes each material stream to the grinding line best suited for processing that particular material type, rather than using a uniform routing approach. This creates localized optimal processing paths for different material types
Solution Approach 2:
The patent performs preliminary routing optimization by pre-configuring blending flows and routing logic based on material properties data and grinding line performance data before materials arrive. The system pre-calculates optimal routing paths and blending ratios, preparing the conveyance network in advance to receive and process materials efficiently, rather than making routing decisions reactively
4Reliability
If the system does not implement overflow management configuration, then the system operation is simpler, but the risk of conveyor overflows increases
Solution Approach 1:
The patent implements preliminary anti-action by proactively preventing conveyor overflows before they occur. The system uses overflow management configuration that monitors approaching capacity limits and adjusts routing and blending ratios in advance to prevent overflows. The system prepares contingency routing paths and adjusts material flow rates before conveyor capacities are exceeded, rather than reacting after overflows occur
Solution Approach 2:
The patent uses dynamic flow management that continuously adjusts material flow rates, routing paths, and blending ratios in response to real-time conveyor load conditions. The system transitions from static flow rates to dynamic control, automatically modulating material flow to match conveyor capacities and prevent overflows through real-time adaptive management
Data Source
AI summary
Methods, systems, and computer storage media for providing a blending flow configuration for a material processing system that blends a material from multiple sources. A blending flow configuration identifies an arrangement of components and settings of the components in the material processing system to support blending a material. The blending flow configuration can support optimizing outcomes of different types of downstream processes. The material properties data are identified based on different types of measurements. For example, block models, lab assays, and on-stream analyzers can be used to determine a composition of the material. Grinding line performance data (or grinding line operation data) that estimates the grinding line performance or capacity can also be accessed. A description of a conveyance network design of the material processing system is generated. The conveyance network design can specifically help identify source nodes, sink nodes, transshipments nodes, and network arcs of the material processing system.