Specific energy reduction in a semi-autogenous grinding mill circuit by an automatic control system
Thomás Pinto1,2, Moisés T da Silva3, Guilherme V Raffo4,5
1Instituto Tecnológico Vale, Robotics, Instrumentation and Control Lab., Ouro Preto, Brazil. thomas.pinto@itv.org.
Scientific Reports
|July 2, 2025
Summary
This study automated grinding operations in a copper plant, reducing energy use by 5.84% and increasing productivity by 1.90% through advanced regulatory control. The new system improved energy efficiency and operational stability.
Area of Science:
- Mineral Processing
- Automation and Control Engineering
Background:
- Grinding operations, particularly semi-autogenous mills, are major energy consumers in mineral processing.
- Mill load variations significantly impact energy consumption and process stability.
Purpose of the Study:
- To apply an advanced regulatory control strategy to improve energy efficiency in a copper plant's grinding operations.
- To demonstrate the benefits of automation in mineral processing through a real-world industrial trial.
Main Methods:
- Implementation of a control system combining cascade and feedforward structures.
- Integration into existing plant automation infrastructure.
- Evaluation through a three-month industrial trial with a focus on feed rate regulation.
Main Results:
- Achieved a 5.84% reduction in specific energy consumption.
- Increased productivity by 1.90%.
- Reduced the influence of process disturbances and maintained more consistent operation through automatic feed rate regulation.
Conclusions:
- Enhanced regulatory control offers a viable strategy for improving energy efficiency and productivity in mineral processing.
- The developed automation system delivers measurable performance gains with minimal disruption to existing operations.
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