Sensor-Embedded Grinding Media for Real-Time Comminution Optimization
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Solution Overview
Problem
Current comminution processes in mineral processing plants face challenges in maintaining energy efficiency and optimizing grinding operations due to the difficulty in real-time data monitoring and dynamic condition responses, leading to high energy consumption and costs.
Innovation Solution
The development of freely moving grinding media equipped with sensors to measure and transmit physical characteristics such as temperature, impact, and vibration data within comminution apparatuses, enabling real-time data collection and optimization of comminution circuit processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional comminution processes are used without real-time monitoring, then device complexity is reduced, but energy consumption increases and process optimization is limited
Solution Approach 1:
The grinding media performs dual function: it both grinds the ore and serves as a mobile sensing platform. The grinding media with embedded sensors monitors its own operational conditions (temperature, impact, vibration) and transmits data wirelessly, eliminating the need for separate monitoring infrastructure and enabling self-optimization of the comminution process.
Solution Approach 2:
The grinding media is designed to perform multiple functions simultaneously: mechanical grinding of ore, real-time data collection on operational parameters, and wireless transmission of process information. This multi-functionality reduces the need for additional dedicated monitoring devices and enables comprehensive process optimization through integrated data from the grinding process itself.
2Measurement precision
If freely moving grinding media with sensors are deployed, then measurement precision of mill dynamics is improved, but device complexity increases
Solution Approach 1:
The grinding media performs dual function: it both grinds the ore and serves as a mobile sensing platform. The grinding media with embedded sensors monitors its own operational conditions (temperature, impact, vibration) and transmits data wirelessly, eliminating the need for separate monitoring infrastructure and enabling self-optimization of the comminution process.
Solution Approach 2:
The patent replaces complex mechanical sensor mounting systems and data acquisition infrastructure with wireless sensor nodes embedded in the grinding media. The sensors communicate via wireless transmission, eliminating the need for physical connections, data cables, and complex signal routing through the mill structure, thereby reducing mechanical complexity while enhancing measurement capabilities.
3Productivity
If real-time data collection from grinding media is implemented, then productivity of comminution optimization is improved, but loss of time for data processing increases
Solution Approach 1:
The system continuously collects real-time data from sensors on the grinding media and feeds this information back to the control system. The feedback loop enables dynamic adjustment of operational parameters during the comminution process, allowing for immediate optimization based on actual process conditions rather than relying on pre-set parameters or delayed analysis.
Solution Approach 2:
The system performs preliminary data processing and analysis at the edge devices or control system before full-scale processing is required. By pre-processing data to extract key insights and trends, the system reduces the computational burden and time required for comprehensive analysis, enabling faster decision-making and optimization actions.
Data Source
AI summary
A grinding media adapted to measure one or more physical characteristics of a comminution apparatus during operation or a charge therein is disclosed. The grinding media includes a freely moving grinding body with a bore disposed in an outer body portion of the body. A sensor body is configured to be received in the bore. The sensor body comprises a rigid sleeve, a resilient core and a sensor array embedded in the core of resilient material. A system for optimizing performance of a comminution circuit is also disclosed. The system includes a comminution apparatus varied in response to one or more physical characteristics of the comminution apparatus or the charge contained therein, measured during operation of the comminution apparatus. The system comprises a plurality of the adapted to measure grinding media. A method of optimizing performance of a comminution circuit is also disclosed.