Grinding Circuit Control via 3D Ore Imaging
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Solution Overview
Problem
Current comminution process control methods in mineral and metallurgical processing are unreliable and inaccurate, leading to inefficiencies in energy consumption and mineral liberation due to variations in ore characteristics and grinding conditions.
Innovation Solution
A method and arrangement that uses 3D reconstruction and particle size analysis to measure and calculate ore characteristics, such as hardness, for continuous optimization of the grinding circuit, incorporating imaging systems and particle size analysis equipment to control the comminution process based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional comminution process control methods are used, then the system is simple to operate, but the control reliability and accuracy deteriorate due to inability to detect ore characteristics variations
Solution Approach 1:
The imaging system performs preliminary measurement of ore characteristics (particle size distribution, shape, density) before the ore enters the grinding circuit. This advance detection allows the control system to predict ore hardness and adjust grinding parameters proactively, improving control reliability without requiring complex real-time monitoring throughout the entire process
Solution Approach 2:
The patent introduces an intermediary calculation model that processes imaging data to derive ore hardness characteristics. This model acts as a mediator between the simple imaging measurements and the complex grinding control requirements, translating visual data into actionable control parameters without requiring direct complex sensing of the grinding process itself
2Measurement precision
If real-time ore characteristic measurement is implemented, then the measurement precision improves, but the device complexity increases due to additional imaging and analysis equipment
Solution Approach 1:
The imaging system is designed to perform multiple measurement functions simultaneously - particle size distribution, particle shape analysis, density estimation, and ore hardness prediction - all through a single multi-functional device. This reduces the need for multiple separate specialized instruments while maintaining high measurement precision across different ore characteristics
Solution Approach 2:
The patent replaces traditional mechanical sampling and laboratory analysis methods with optical imaging systems. Instead of physically collecting ore samples for manual or mechanical analysis, the system uses non-contact optical fields to measure ore characteristics, eliminating complex mechanical sampling equipment and reducing overall device complexity while improving measurement precision
3Productivity
If continuous monitoring of ore characteristics is performed, then the productivity improves through optimized grinding parameters, but the use of energy increases due to additional measurement and control systems
Solution Approach 1:
The system dynamically changes grinding circuit parameters (mill speed, feed rate, classifier settings) based on detected ore characteristics. When softer ore is detected, the system reduces grinding intensity and energy input; when harder ore is detected, it increases energy input only when necessary. This adaptive parameter adjustment optimizes productivity while minimizing unnecessary energy consumption throughout the grinding process
Data Source
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AI summary
The present invention relates to the field of mineral and metallurgical processes, to comminution processing or disintegrating in general and to comminution processing by crushers and tumbling mills, and more particularly to a method and an arrangement for controlling a comminution process having a grinding circuit. An arrangement for controlling a comminution process according to the present invention having a grinding circuit (8), (20), (31), which arrangement comprises an imaging system (22), (27) measuring 3D reconstruction measurement data (33) for three-dimensional reconstruction of incoming ore (9), (21); a particle size analysis equipment (28) measuring particle size data (34) for calculation of the particle size characteristic value (38) of outgoing ore (10), (32); an ore characteristics data calculation block (39), said ore characteristics data calculation block (39) receiving a particle size distribution profile (36) of incoming ore (9), (21) and a particle size characteristic value (38) of the outgoing ore (10), (32), the said particle size distribution profile (36) being calculated and/or reconstructed from the said 3D reconstruction measurement data (33) for three-dimensional reconstruction, and the said particle size characteristic value (38) being calculated based on the said measured particle size data (34), said ore characteristics data calculation block (39) calculating ore characteristics data (41) based on the said particle size distribution profile (36) and the said particle size characteristic value (38); and a control block (44), (51) controlling the grinding circuit (8), (20), (31) based on the said calculated ore characteristics data (41).