Process plant optimisation techniques have become a necessity for mines looking to maximise their operating performance by keeping costs low, throughput high and downtime to a minimum.
FLSmidth’s automated SmartCyclone system is a solution that delivers in all three areas for cyclone circuits, a vital processing element in any plant.
It is a monitoring and control solution for reducing cyclone-related process deviations. It also improves overflow particle size distribution, predicts and controls cyclone maintenance schedules, and optimises closed-circuit grinding processes.
This equates to monitoring the performance of individual cyclones within a circuit in real time, preventing unplanned breakdowns from occurring and monitoring wear rates while ensuring the cyclones are operating optimally at all times. This translates into higher efficiencies in the plant and ultimately, higher profitability.
Technology to sense malfunctions
The SmartCyclone closed circuit grinding optimisation system combines a variety of FLSmidth patented technologies which includes the Krebs SmartCyclone wear detection sensor technology as well as the Krebs’ patented roping sensor technology with a wireless controller system. This immediately identifies if a cyclone is malfunctioning.
The closed circuit grinding optimisation system also incorporates FLSmidth’s ECS/ProcessExpert process control software with a SmartWear cyclone maintenance algorithm. One of the largest benefits associated with this software is the ability to develop a uniform operation strategy that outlines the best way to run the plant. Once this strategy has been established, the necessity to train new operators is reduced.
Reducing or eliminating manual operation, which decreases the potential for human error, is in fact one of the overarching benefits of SmartCyclone.