Better Crushing and Grinding with Rock Sizing Cameras

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Calibrating a pair of stereo cameras.

Calibrating a pair of stereo cameras.

Our rock sizing software uses two methods to model the ore, a segregation and breakage model, and blends them intelligently for the most accurate particle size distribution analysis. Our rock sizing camera installations include robust, cost effective, and battle proven hardware combinations to compliment our industry leading PlantVision™ course particle size analysis software.

KnowledgeScape has pioneered the use of image analysis systems in minerals processing plants throughout the world. Over the years we have perfected the complex algorithms behind our image analysis software and created the most trusted coarse particle size analysis software available. PlantVision™ is not only exceptional from a technical standpoint, as it is also extremely user friendly for both operations and maintenance staff.

Operators will have realtime access to all measurements, and can easily define areas of interest in realtime with drag and drop functionality from their workstation. Other parameters are easily tuned within the user interface as well.

The maintenance staff will enjoy an industry best calibration procedure which requires minimal manpower or downtime. To calibrate other systems, you typically have to take a very long belt cut, run the belt under the camera, and then stop the belt. This is hard for the lab, requires moving a lot of material at once, and limits the mounting locations to positions further from the mill. With PlantVision™ we simply stop the belt and shovel the area directly under the camera, and we are done. This is easily done in a few minutes during  maintenance times, and each cut is just a few 5 gallon buckets of muck, as opposed to several 55 gallon drums.

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PlantVision™ software runs as a Windows service meaning that it runs in the background and can be used in a server environment with no need for a person to start and stop it. The software monitors itself, and can detect and respond to camera failures and software crashes. A graphical user interface can be attached to monitor and configure the system, and to display real-time updates to operators and metallurgists. 

PlantVision™ easily interfaces to DCS, PLC, data historians, or the KSX expert control software. PlantVision ™ can interface with a wide variety of available camera types, allowing for the ultimate installation flexibility and customization. PlantVision™ can use USB, Firewire, IP (Internet Protocol), CameraLink, or Analog (Coax Video) cameras. All of our hardware selections have been battle tested and proven to provide the most reliable, productive, and cost effective solutions for our customers.

Improve Grinding and Crushing Circuit Performance

PlantVision™ Coarse Particle Size analysis software is a valuable component of your grinding and/or crushing control strategy. The data is made available over industry standard OPC communication, and can be used by our KSX expert system to have an integrated solutions that can forecast process responses for multiple set point changes, while simultaneously accounting for multiple objectives, and ultimately select the approach yields the best possible outcome. With realtime feed data being provided to KSX by the PlantVision™ system, disturbances in feed can be accounted for before traditional control variables can even detect the disturbance.

Our experience integrating coarse particle size software, to the KSX expert control strategies, is second-to-none, and our GrindingExpert™ solutions will ensure maximum throughput for the concentrator.

For crushers, we can use PlantVision to analyze the crushed product and “take up” any underperforming crusher to account for the nonlinear wear patterns and performance hinderances that will always occur with time and ensure the most uniformed and consistent ore size to downstream processes.

For SAG mills, rock sizing cameras can be a valuable asset when trying to increase throughput. In a control strategy, adaptive targets are subjected to the constraints of the particle size analysis. The system can adjust the set points to ensure that the mills are operating at peak efficiency. KSX will achieve this by constantly monitoring the control variables, including the ore properties, to maintain the optimal volumetric loading. For example, in a SAG mill, where we are relying on bearing pressure as a proxy to estimate volumetric mill loading, different adaptive bearing pressure ranges will be targeted based on measured feed size. The mill will be watched closely, looking at the magnitudes, and the rates of change of the control variables (1st and 2nd derivative) to make determinations about the current feed rate, volumetric loading, and grinding efficiency. For example, as ore size increases, the strategy will seek to maximize the lifting of the ore in the mill, so that the falling rock has the greatest kinetic energy as it cascades,. This approach will break large ore much more efficiently than attrition grinding.  With finer ore, the strategy will seek out the optimal volumetric loading target to utilize the benefits of attrition grinding to maximize throughput.

The end result is a highly adaptive,  dynamic , robust, and cost effective solution that will reliably and repeatably increase the throughput of your mill.

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