Optimal mill loading with smart sensor technology

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.

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.