Optimal mill loading with smart sensor technology
Optimal mill loading ensures you are making the most efficient use of your grinding mill – but in the past, it has been difficult to calculate the optimal mill load with precision. Not anymore. KnowledgeScape™ LoadIQ™ utilises our mill scanner smart sensor technology to determine the optimum mill load, increasing throughput by 3 – 6%.
Maximum grinding efficiency, with minimum effort
You don’t need to upgrade your grinding mill to increase capacity – you just need to make the most of the system you have. With LoadIQ you can optimise mill load using a system of smart sensors and AI software. Typical throughput increases of 3 – 6% are being seen in concentrators around the world, with some customers benefiting from a 10+% increase in tonnage.
LoadIQ utilises our mill scanner smart sensor technology to accurately measure volumetric filling and ore trajectory in real-time. It then combines this reading with data about the ore type and liner profile to determine the optimum mill load. Mill operating parameters are then automatically adjusted in real time as grinding conditions change.
LoadIQ can also be configured as a standalone solution, where it will send a suggested load target and RPM to the operators or existing expert system.
LoadIQ: Intelligent mill loading for optimum performance
Maximise throughput for all grinding conditions
Using smart sensors and machine learning, LoadIQ automatically reacts to changes in grinding conditions, such as liner wear or ore characteristics, to ensure you are always targeting the optimum mill load.
Smart system reacts to changing parameters in real-time
No lag time while you wait to see the impact of new operating parameters – LoadIQ runs continually and uses real-time data from your system as well as its own intelligent algorithm to calculate the appropriate mill load.
Reduce liner damage
By preventing overloading of the mill, liner damage is reduced – giving you longer wear life from your liners and reducing maintenance costs and downtime.
Increase energy efficiency
By operating at optimum load, you reduce power consumption and increase operational stability.
Integrates well with existing control systems
If you already have an expert system and don't want to use the LoadIQ automatic adjustments, LoadIQ compliments any existing expert system grinding strategy by providing dynamic limits. This means that nothing is actually changed in the expert system, the expert system is just given better limits to operate within. This approach allows for rapid integration, adoption, and the best real-world results.
Want to reach the extra mile of optimisation?
For the best possible results, we recommend integrating with ECS/ProcessExpert®, our Advanced Process Control System. This will provide your business with greater flexibility as together they will automate the response to mill conditions, freeing up your operators for other roles. We have designed ECS/ProcessExpert to adjust mill conditions to improve ore reduction and energy efficiency to help lift your productivity. Learn more about the benefits of ECS/ProcessExpert here.
How does LoadIQ achieve optimal mill load?
It’s true: previous tools aimed at optimising mill load were not always successful. They were judging volumetric load – how full the mill is – by bearing pressure, a flawed measurement.
Data analysis and real time smart sensor data
Bearing pressure doesn’t account for ore size changes (interstitial spacing affecting density), and this measurement is also confused by changes in oil temperature, mill direction, liner wear, and mill density.
LoadIQ utilises cutting edge mill scanner smart sensor technologies to bridge these gaps and accurately measure volumetric filling and ore trajectory in real time. We then use large scale data analysis and real time smart sensor data to correlate maximum breakage rates to the incoming ore types as well as the current liner profile.
Liner wear is directly correlated to the ore trajectory in a grinding mill for a given RPM. As the liners wear, the ability to strike the toe at higher volumetric fills may not be possible. In cases where this is true, the volumetric load will automatically be decreased until the toe is impacted, thus restoring maximum efficiency. Conversely, with a new set of liners, the trajectory at high RPM will likely cause excessive liner strikes. In these cases, LoadIQ automatically reduces the maximum allowable RPM such that the cascading ore is impacting the charge toe.