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.

  • 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

    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,ÌýDr Richmond Asamoah
    • Research lead:Ìý±«²Ô¾±³§´¡
    • Translation partner: Manta Controls

    This project is linked to Translation Projects 7 and 8 (B TP7, B TP8).

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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: ³ÉÈË´óƬ
    • Translation partners: Manta Controls

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  • Research project 3 (B RP3): New sensor development for particle size in hydrocyclones
    Difan Tang

    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: ³ÉÈË´óƬ
    • Translation partners: Manta Controls

    This project is linked to Translation Project 8 (B TP8).

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Stage project B2: floating circuit

These project are part of Research Group 2 - Flotation

  • Research project 4 (B RP4): Sensing and optimisation of flotation circuits and integration with grinding

    This project has been completed.

    Bismark Amankwaah-Kyeremeh

    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,ÌýDr Richmond Asamoah
    • Research lead:Ìý±«²Ô¾±³§´¡
    • Translation partners: Manta Controls, Magotteaux

    This project is linked to Translation Projects 8 and 9 (B TP8, B TP9).

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Stage project B3: tails leach circuit

These project are part of Research Group 3 - Leaching

  • Research project 5 (B RP5): Metal organic framework based fibre-optic sensors

    This project has been completed.

    Linda Rozenberga

    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:Ìý±«²Ô¾±³§´¡
    • Translation partners:Ìý²Ñ²¹²µ´Ç³Ù³Ù±ð²¹³Ü³æ

    This project is linked to Research Project 6 (B RP6) and Translation Project 10 (B TP10).

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  • Research project 6 (B RP6): Diffusive processes in mineral processing

    This project has been completed.

    Kirsten Louw

    Kirsten Louw

    This project aims to model diffusion of Fe3+Ìýions in MOF and solve non-linear diffusion equation with application to population dynamics. The governing equation will be solved using symmetry analysis.

    • ³§³Ù³Ü»å±ð²Ô³Ù:ÌýKirsten Louw
    • Principal supervisors: A/Prof Bronwyn Hajek, Prof William Skinner
    • Postdoctoral fellow: Dr Richmond Asamoah
    • Research lead:Ìý±«²Ô¾±³§´¡
    • Translation partners:Ìý²Ñ²¹²µ´Ç³Ù³Ù±ð²¹³Ü³æ

    This project is linked to Research Project 5 (B RP5).

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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.

    Todd Gillam

    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:Ìý±«²Ô¾±³§´¡
    • Translation Partner:Ìý²Ñ²¹²µ´Ç³Ù³Ù±ð²¹³Ü³æ

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Translation projects

  • Translation project 7 (B TP7): Manta Mic Acouster Analyser

    This project has been completed.

    Dr Richmond Asamoah

    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

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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

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  • Translation project 9 (B TP9): Pulp Chemistry Monitor for improved predictive flotation model and process performance
    Dr Richmond Asamoah

    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:Ìý³Ù²ú³¦
    • Translation Partners: Manta Controls, Magotteaux

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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:Ìý²Ñ²¹²µ´Ç³Ù³Ù±ð²¹³Ü³æ, Rockwell Automation

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  • Translation project 11 (B TP11): Development of laboratory AG/SAG mill

    This project has been completed.

    Dr Richmond Asamoah

    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:Ìý²Ñ²¹²µ´Ç³Ù³Ù±ð²¹³Ü³æ

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