Hydrocyclone Overflow Size Control Using Multi-Point Particle Measurement
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Solution Overview
Problem
Existing mineral processing technologies face limitations in controlling final ground product size in real-time due to the lack of robust sampling instruments, which restricts the development and implementation of effective control strategies for hydrocyclone batteries in mineral extraction systems.
Innovation Solution
A controller with a signal processor configured to receive and analyze multiple particle size measurements from hydrocyclone classifiers, determining control signaling to optimize the ground product size and floatable fraction for individual hydrocyclones, enabling real-time automatic control and maximizing Net Metal Production (NMP) in mineral processing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sampling instruments are used to measure ground product size, then measurement capability is provided, but instrument availability and reliability are poor due to lack of robustness and maintenance requirements
Solution Approach 1:
The patent replaces traditional mechanical sampling instruments with an acoustic measurement system that uses sound waves to measure particle size. The acoustic impactor uses acoustic energy instead of mechanical moving parts to detect and measure ground product size in real-time, eliminating the reliability issues associated with mechanical wear and maintenance requirements.
Solution Approach 2:
The patent introduces an acoustic field as an intermediary between the ground product and the measurement system. The acoustic impactor uses sound waves to interact with particles in the slurry stream, allowing non-contact measurement that does not require physical sampling or complex mechanical components, thereby improving measurement availability and reliability.
2Productivity
If only single particle size measurement is used, then control strategy is simple, but control effectiveness is limited and cannot optimize floatable fraction
Solution Approach 1:
The patent segments the particle size measurement into multiple discrete size measurements (e.g., P80, P90, P95) rather than using a single measurement. This allows the control system to optimize different aspects of the particle size distribution independently, maximizing the floatable fraction while maintaining control effectiveness. Each particle size measurement provides specific information for targeted optimization.
Solution Approach 2:
The patent implements a measurement system that provides multiple particle size measurements simultaneously using a single acoustic impactor device. This multi-functional measurement capability enables comprehensive control optimization without requiring multiple separate measurement instruments, maintaining simplicity while improving control effectiveness.
3Productivity
If real-time control is implemented with multiple particle size measurements, then optimization of floatable fraction is achieved, but control system complexity increases
Solution Approach 1:
The patent implements a feedback control system where multiple particle size measurements are continuously monitored and fed back to the control algorithm. The controller adjusts mill operational parameters based on real-time feedback from the acoustic impactor measurements, optimizing the floatable fraction and maximizing Net Metal Production through closed-loop control.
Solution Approach 2:
The patent changes the control parameters from single particle size control to multi-parameter control involving multiple particle size measurements (P80, P90, P95) and their relationships. This allows the control system to optimize the particle size distribution shape and maximize the floatable fraction by adjusting multiple parameters simultaneously based on the measured relationships between different size fractions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the availability and reliability of particle size measurements, allowing for advanced control strategies that improve the separation of valuable ore from waste, increasing the efficiency and productivity of mineral processing operations by optimizing the particle size range for flotation recovery.
Implementation Method 1
a new particle size measurement technology based on acoustic impact principles
Implementation Method 2
hydrocyclone classifier overflow stream
Data Source
AI summary
A mineral processing system featuring a controller having a signal processor or processing module configured to: receive signaling containing information about a relationship between multiple particle size measurements of different measured particles having different measured particle sizes flowing in a hydrocyclone classifier overflow stream sensed by at least one particle size measurement device arranged on a hydrocyclone classifier overflow pipe of at least one hydrocyclone in a hydrocyclone battery, and about a floatable fraction that defines a particle size range of different floatable particle sizes of different floatable particles that can be recovered by the at least one hydrocyclone in the hydrocyclone battery; and determine corresponding signaling containing information to control a ground product size of ore having ground particles provided to the at least one hydrocyclone in the hydrocyclone battery, based upon the signaling received.