Case Study

10% increase in the productivity of the grinding process

How the Nebuluz expert system made major improvements in the production of a large mining company

Mining

From crushing to transport, solutions with great experience of the processes

Project Data

OTIMIZATION

10%

to increase grinding productivity

Result proven and validated by the customer himself

SATISFACTION

93%

user

Accepted by most operators, Nebuluz has become the company's standard APC

PERFORMANCE

87%

stabilization time reduction

The time has been reduced from 4 hours to 30 minutes

Context and Challenges

The client was initially looking for a 3% improvement in grinding productivity. During the execution of the project the initial objective was changed: the real need of the process became to achieve an optimized mass partition between the fine and coarse circuits, maintaining the granulometry as specified. In this context, the implementation of Nebuluz went through the following challenges:

  1. Solve the problems of the thinner circuit, which was saturated
  2. Reviewing the regulatory control system, which proved inefficient
  3. Search for a solution to the unavailability of the particle size analyzer
  4. Provide complete information for the mass balance, which was done with insufficient data
  5. Meeting the expectations of the client, who had had bad previous experience with a market specialist system

Solutions Used and Equipment Provided

An assessment of regulatory control was made, with strategy review and implementation of a number of improvements

We built a Density Softsensor to increase the reliability of the mass balance

We did a process modeling and developed a design for the advanced control strategy

Commissioning and Startup were done using agile methodology

Experts

Control Systems Specialist

Leonardo of God

Innovation and Consulting

Juliana Martins

Head of Innovation

Rudá Martins

Awards

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Whitepapers

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10% increase in the productivity of the grinding process

How the Nebuluz expert system made major improvements in the production of a large mining company

January 25, 2021

published by

Control Systems Specialist

Leonardo of God

published by

Innovation and Consulting

Juliana Martins

published by

Head of Innovation

Rudá Martins

OTIMIZATION

10%

to increase grinding productivity

Result proven and validated by the customer himself

SATISFACTION

93%

user

Accepted by most operators, Nebuluz has become the company's standard APC

PERFORMANCE

87%

stabilization time reduction

The time has been reduced from 4 hours to 30 minutes

The client was initially looking for a 3% improvement in grinding productivity. During the execution of the project the initial objective was changed: the real need of the process became to achieve an optimized mass partition between the fine and coarse circuits, maintaining the granulometry as specified. In this context, the implementation of Nebuluz went through the following challenges:

  1. Solve the problems of the thinner circuit, which was saturated
  2. Reviewing the regulatory control system, which proved inefficient
  3. Search for a solution to the unavailability of the particle size analyzer
  4. Provide complete information for the mass balance, which was done with insufficient data
  5. Meeting the expectations of the client, who had had bad previous experience with a market specialist system

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