Key Benefits

  • Improved mineral recovery
  • Stabilised cyclone operation
  • Continuous wear monitoring and management
  • Predictable cyclone circuit maintenance
  • Increased production capacity: the process can be operated closer to the limits of the cyclone manifold design

Reduce process perturbations, improve overflow particle size distribution

Numerous processing plants around the world have reduced costs related to wear and “roping” – the condition known to occur when the apex capacity is exceeded in closed-circuit grinding.

Wireless communication and live operating data

The SmartCycloneTM solution combines wireless wear-detection sensors and roping sensor technology with a centralised, handheld wireless controller. The controller can communicate with up to 16 wireless sensors per unit providing real-time detection and communication of roping and wear data from the SmartCyclone sensors for forwarding to the control room workstation. The SmartCyclone closed-circuit grinding optimisation system helps plant operators reduce cyclone-related process perturbations, while improving cyclone overflow particle size distribution


The controller unit allows the user to easily set operating parameters for any desired sensor. When the controller unit is reconnected to its docking station, it charges itself and communicates live operating data back to the control room.


With a SmartCyclone-equipped process, the cyclone sensors help indicate the functional state of the cyclone by monitoring the conditions of the slurry flow for each cyclone individually to optimize downstream particle size. This particle size distribution has a direct impact on the efficiency of downstream processes, such as flotation. Real-time condition monitoring solutions have not been common in such circuits, but that is changing as it helps optimise the flotation feed and maximise production.


Reduce manual involvement

The SmartCyclone runs on the field-proven ECS/ProcessExpert® (PXP) process control software. The ECS/ProcessExpert system is a modern, advanced process control solution used to stabilise and then optimise key minerals processes. It balances equipment loads, manages and corrects process disruptions, and minimises wear on the plant’s equipment – all by dramatically reducing manual involvement from mill operators.

The ECS/ProcessExpert solution also enables a minerals plant to develop a uniform operation strategy that outlines the best way to run the plant. Once this strategy has been established, training new operators becomes much easier.


It is also beneficial in predicting and controlling cyclone maintenance schedules. The sensors report the wear status of the cyclone components, so that parts purchasing and maintenance operations can be planned with greater control.


Overall, the SmartCyclone system will help a closed-circuit grinding process achieve a level of automation with process efficiencies previously not possible with conventional processing equipment alone. Extended cyclone life and increased operational efficiency lead to the ideal outcome – improved comminution productivity, improved recovery and higher profitability.

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