Key Benefits

  • Less process down-time
  • Improved mineral recovery
  • Improved process stability and wear monitoring
  • Increased production capacity

Wireless automation package for detecting cyclone roping and wear

SmartCyclone™ solutions for process optimisation are available in three main levels of sophistication, starting with the Basic package.

Our underflow sensors detects cyclone-related process upsets known as roping and allow you to quickly improve cyclone overflow particle size distribution.

Our SmartCyclone wear sensors allow you to predict and control cyclone maintenance schedules.


Basic package Sensor input Control action
Roping detection* Alarm only
Wear detection* Alarm only
Cyclone on/off via valve position Display only
Standard package Sensor input
Control action
Roping detection Alarm & off/on cyclones
Wear detection Alarm & off/on cyclones
Manifold valve position Alarm & off/on cyclones
Smart wear timer Turns off/on cyclones (to address roping events and manage wear)



Monitoring for Upsets with SmartCyclone sensors that can detect a roping event.

Quick identification and correction of process upsets

SmartCyclone™ is a control solution that is packaged to meet your needs – whether it is for basic detection or fully optimising your cyclone system. It targets the closed-circuit grinding process with a dedicated automation philosophy – helping your plant achieve maximum process efficiency.

Less process down-time

With our quick perturbation identification you can act on the upset and reduce your downtime.  An example of perturbation recovery: Opening and closing cyclones, and other control actions to accommodate process interruptions, like cyclone roping.

Improved mineral recovery
Enhanced process monitoring leads to reduced variation in flotation particle size distribution, therefore improving mineral recovery.
Predictable cyclone maintenance

Monitoring the system for wear allows for a more precise maintenance schedule.

Increased production capacity
By adding a mechanism which the plant operator can use to monitor roping, the process may be operated closer to the limits of the cyclone manifold design, therefore improving production capacity.

Real-time wireless detection and communication of roping and wear data

Condition monitoring

Condition monitoring is the process of using sensors to observe parameters of critical machinery in order to identify significant changes that may indicate a developing problem. You want to make sure you are on top of these before major issues arise. Our SmartCyclone™ Basic is a simple solution which detects cyclone-related process upsets and allows you to quickly improve cyclone overflow particle size distribution.. It also aids you to predict and control cyclone maintenance schedules.


Wireless technology and automation

The compact, wireless SmartCyclone sensor system eliminates the need for individual node boxes, as well as the interconnecting cables between the sensors and nodes and associated controllers. SmartCyclone technology operates with a centralised, handheld wireless controller that can communicate with up to 16 wireless sensors per unit, providing real-time detection and communication of a condition known as roping (a breakdown in classification) and wear data from the SmartCyclone sensors for forwarding to the control room workstation.


Greater control to plan ahead

The sensors can report the wear status of the cyclone components, giving your operation greater control to plan ahead for parts purchasing and maintenance scheduling. The sensors can also report when a cyclone is malfunctioning – such as when an individual cyclone experiences roping.


If you want to take your cyclone standard monitoring and optimisation to the next level them make sure to check out our SmartCyclone Expert systems. We combined our SmartCyclone sensor technology with our proven ECS/ProcessExpert advanced process control software to deliver maximum process efficiency

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