Critical variables difficult to observe
The critical variables of the mill cannot always be measured directly, and evaluating operational scenarios in the physical asset involves risk, time, and loss of production.
Digital replica for diagnosis and optimization
100% digital platform that replicates the behavior of the SAG mill using operational data, mineral characteristics, and design information. Provides calculated variables, alerts, analysis, and simulations to support control and optimization decisions.
Benefits
Software-based flexibility
Operates entirely through software, with no additional hardware required, integrating specialized modules, customized simulations, alerts, recommendations, and self-calibration.
Greater visibility of variables
Provides visibility of variables that are difficult to measure directly.
Evaluation without intervention
Allows evaluation of scenarios and recommendations without intervening in the mill.
Stability and throughput
Supports operational stability, liner protection, and optimization of throughput by at least 2%.
How Does the Solution Work?
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Operational Modules
JB and JC
Real-time monitoring of total mill filling (JC) and ball filling (JB).
Liner Wear
Prediction of maximum lifter height and attack angle.
Charge Position
Analysis of charge position based on toe, shoulder, and impact angles.
Charge Toe Size and Impacts
Monitoring of charge toe size and dynamic impact thresholds.
DEM Simulator
Optimized DEM simulator integration through One Click DEM.
Grate Blockage Detection
Quantifies the level of grate blockage in the SAG mill.
Full Lifter Profile Prediction
Predicts the complete lifter and plate profile based on 41 tracked points.
Inventory Request
Provides target Jc charge level guidance to support maintenance planning.
SAG Mill Operating States
Identifies overfilling and emptying events and provides optimization guidance.
Throughput Optimizer
Maximizes throughput according to charge toe size.
Ball Addition Optimizer
Estimates ball mass loss and optimizes ball addition to achieve the target Jb.
Optimal Load Cell Setpoint
Defines the optimal load cell setpoint according to campaign time.
Perfect Blend (+B&R)
Optimizes SAG mill feed particle size distribution through feeder speed adjustments.
T80 Optimizer (+B&R)
Optimizes SAG mill product size (T80).
Ramp-Up Reduction
Defines strategies to reduce ramp-up time.
Rotation Direction Strategy
Optimizes changes in rotation direction to maximize useful life or lifter performance.
Turning Operational Data to Actionable Insights
All Digital Solutions solutions
17 solutions available