Patent Application
20240017268
The present disclosure generally relates to detection systems and, more particularly, to detection systems for detecting and monitoring comminution mill operation conditions.
For the extraction or dressing of mineral material from ore, freshly supplied ore material is typically prepared in several process stages, the first of which is the preparation process including a suitable comminution of the fresh ore material supplied from a mine. This comminution, or mechanical pulverization, of the ore material enables the valuable mineral material (typically a mineral ore in the case of most mining operations) to be separated and segregated from waste material. The comminution process typically commences at the point of extraction of the ore material from a mine or surface digging, but then typically involves a crushing stage followed by a grinding stage to achieve a fine material size suitable for the mineral extraction process. Depending on the properties of the ore, as well as the grinding technique, that is used, the mineral material can be crushed to a maximum lump size varying between about 500-100 millimeters (mm).
In one aspect, a comminution mill sensor system is provided. The comminution mill sensor system can include a plurality of shell sensor assemblies. Each of the plurality of shell sensor assemblies can include: at least one sensor or sensor array, at least one energy source, and at least one antenna. Each of the plurality of shell sensor assemblies is coupled to a comminution mill grinding compartment. The plurality of shell sensor assemblies are adapted to provide for a plurality of mill interior measurement zones within the comminution mill grinding compartment.
In another aspect, a method for monitoring comminution operation conditions is provided. The method can include receiving sensing data from a plurality of shell sensor assemblies during operation of a comminution mill. Each of the plurality of shell sensor assemblies can include at least one sensor or sensor array, at least one energy source, and at least one antenna. Each of the plurality of shell sensor assemblies can be coupled to a comminution mill grinding compartment of the comminution mill, at spaced apart positions so as to provide a plurality of mill interior measurement zones. The method can also include determining a two-dimensional process map, a three-dimensional process map, or both, based on the sensing data.
Illustrative aspects of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:
The subject matter of aspects of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, it is contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies.
In this specification where a document, act, or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act, or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of the common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is concerned.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
Representative aspects of the present disclosure relate, generally, to various apparatus, methods, and systems of detecting a mill charge during comminution and/or for monitoring comminution mill operations. In the same or alternative aspects, the systems and methods disclosed herein are related to systems and methods for modelling a mill charge during comminution. The disclosure has particular, but not necessarily exclusive, application to detecting and/or modelling a mill charge during comminution of ore material in a mining and/or mineral processing context. However, it should be understood that the disclosure is not limited to these representative aspects, and may be implemented in other environments using a comminution mill apparatus
There are a number of known methods and apparatuses for the grinding comminution of ore. Certain conventional methods and apparatus involve the use of horizontal grinding mills and include: autogenous (in which grinding is done by utilizing grinding bodies from the ore material itself); semi-autogenous (in which grinding is done in part by the ore material itself, and in part by grinding media (typically, steel balls) which are partially substituted for the ore material in small quantities); and conventional (in which grinding is done exclusively by steel rods within the mill and grinding media (typically, steel balls)).
Within the mineral processing industry, the comminution of an ore material, with the aid of autogenous grinding techniques, generally takes place in three primary ways. Firstly, by impact, being the shock of the ore material falling onto a substructure or against the material itself. Secondly, by attrition, being the most common in rod and ball mills (e.g. conventional and semi-autogenous mills) and in autogenous mills (under favorable conditions). Attrition refers to the process of smaller ore pieces being comminuted by pressure and shearing between larger ore pieces and/or between surfaces under pressure. Thirdly, by abrasion, wherein comminution occurs as a result of the surfaces of pieces of ore material being rubbed/worn against each other. This type of comminution typically requires a large amount of energy and often results in an inconsistently ground ore product.
The comminution technique adopted by a particular mining or mineral processing operation is highly dependent on the ore material being mined, its comminution properties, and/or its ‘grinding resistance’. Ore materials are typically classified according to certain competence ranges that guide the selection of the comminution technique. The first is ‘competent’, referring to ore materials having sufficient mechanical strength to form an active grinding charge in their own right, making them well-suited to autogenous grinding techniques. The second is ‘incompetent’, referring to ore materials requiring the addition of foreign grinding media (e.g., steel balls) to enable their comminution, making them well-suited to semi-autogenous or conventional grinding techniques. The third is ‘over-competent’, referring to ore materials which have very high mechanical strength where their comminution in an autogenous grinding process requires very high energy input, making them more suited to conventional or semi-autogenous grinding techniques.
Historically, the conventional grinding technique (involving the exclusive use of steel rods and balls for grinding) has been used most extensively in the mining industry, and is typically preceded by extensive crushing of the mineral material or ore before grinding as it produces a more stable grinding process, due to the grinding charge being homogeneous in weight and composition. However, this conventional technique is also the most expensive of the grinding techniques mentioned, in terms of both the initial capital investment and ongoing operational expenses.
In accordance with the autogenous technique, a certain proportion of the comminuted material can optionally be recirculated in the mill. Alternatively, certain configurations may include at least one drum mill or agitator mill (arranged after an autogenous mill) in which the comminuted product obtained in the autogenous mill is then reground to the desired fineness of the finished product. These mills can also be interconnected with a classifier so that the ore material is comminuted in a closed circuit and sufficiently fine material is drawn off from the classifier as finished material. An autogenous mill is a type of drum mill of relatively large diameter in which the ore material itself forms the grinding elements. However, such autogenous mills can also include a limited proportion of additional grinding media (such as, for example, steel grinding balls) to assist with the comminution process. This latter type of comminution operation is commonly referred to as a semi-autogenous or SAG mill.
Often with the use of comminution techniques that involve conventional or semi-autogenous grinding (especially drum mills that incorporate steel rods and steel balls as grinding media), it is desirable to observe, monitor and optimize the operating characteristics of the grinding media within the drum. However, due to the harsh nature of the internal environment within the drum (during operation), it is typically not feasible to use sensor or camera/vision systems as the rotational movement of the ore material and grinding media within the drum will likely damage and destroy these systems within a short period of time.
The ability to maintain a constant total load volume in a mill (e.g. SAG mill) at the required feed rate can be an important control requirement. For this reason, certain conventional systems can use loads cells and or acoustic sensors to provide an indication of changes in load level in the mill. However, SAG mills are difficult to operate on power alone, as the power to mill load relationship is not consistent. The power draw to mill load relationship can be affected by changes in the milling density as a result of changes in viscosity and charge fluidity. Furthermore, slurry transfer through and out of the mill affects the size of the slurry pool within the mill and the size of the slurry pool affects power draw. Therefore, changes in circulating load on a single stage mill may affect the size of the slurry pool and consequently the power draw.
Therefore there is a need for a system that can monitor and/or model the comminution process and/or a mill charge during a comminution operation.
As discussed above, at a high level, the systems and method disclosed herein include detection systems for detecting and/or modelling mill charge behavior during comminution, as well as monitoring comminution mill operation conditions. In various aspects, the systems and method disclosed herein can include a plurality of shell sensor assemblies that are coupled to the comminution mill grinding compartment and that can provide detection and information related to a mill charge during comminution. In aspects, this information can be transmitted outside of the comminution mill grinding compartment and can be utilized to provide two- and/or three-dimensional process maps or models of the mill charge during comminution. In various aspects, the systems and methods disclosed herein can provide for real-time monitoring and/or detection of a mill charge and/or comminution operation conditions which can lead to improved operation of the mill charge.
In aspects, the comminution mill 120 depicted in
In the aspect depicted in
As discussed above, in aspects, the plurality of shell sensor assemblies 110 are operable to communicate sensor data to the receiver 130 that is positioned outside of the comminution mill 120. In the same or alternative aspects, the plurality of shell sensor assemblies 110 can wirelessly communicate sensor data to the receiver 130, e.g., using any convenient wireless communication technology.
In various aspects, the plurality of shell sensor assemblies 110 can be capable of detecting various types of information associated with the mill charge and/or the operation of the comminution mill. The shell sensor assemblies and specific components are discussed in detail further below. The information detected and/or sensed by the plurality of shell sensor assemblies 110 and communicated to the receiver 130 allows for the receiver 130 to provide modelling and/or process maps of the mill charge during comminution mill operation. As discussed further below, this modelling and/or process mapping of the mill charge during comminution can allow for improved comminution mill operation.
While the plurality of shell sensor assemblies 110 can provide detailed information associated with the mill charge and/or operation of the comminution mill, a plurality of mill charge media sensor elements 140 can optionally be included in the comminution mill sensor system 100, in aspects. The specific features of the mill charge media sensor elements 140 are discussed in detail further below primarily with reference to
In aspects, the mill charge media sensor elements 140 can be freely moving just like the mill charge in the comminution mill, and can sense and/or detect information on the mill charge as well as operating conditions within the comminution mill 120. In aspects, the mill charge media sensor elements 140 can communicate data obtained from onboard sensors to one or more of the shell sensor assemblies 110, which can then in turn communicate this information to the receiver 130. In such aspects, the receiver 130 can utilize the information from both the mill charge media sensor elements 140 and the shell sensor assemblies 110 to provide modelling and/or process maps of the mill charge during comminution mill operation.
In the aspect depicted in
In the aspect depicted in
In certain aspects, a shell sensor assembly can be coupled to the comminution mill and/or comminution mill grinding compartment in other positions and/or in other manners not requiring a liner bolt. For instance,
In certain scenarios, transmitting data from within certain metal environments to an external receiver may be difficult due to a dampening or inability for electromagnetic radiation to escape certain metal structures, if present. In various aspects, the systems and methods disclosed herein can provide consistent communication of sensed data and/or process data from within a comminution grinding compartment to an outside or external receiver. For example, in certain aspects, at least a portion of an antenna of the shell sensor assembly may extend from the comminution compartment past the mill shell and/or to the mill shell for transmitting the process data and/or sensed data.
As depicted in
In certain aspects, the shell sensor assemblies can be positioned in an interior portion of the comminution mill, e.g., an interior portion of a comminution mill grinding compartment. For instance, in
In various aspects, individual shell sensor assemblies can be coupled both to an interior portion of a comminution mill grinding compartment and to an exterior portion of a comminution mill grinding compartment. For instance, in the aspect depicted in
In certain aspects, the systems and methods disclosed herein can optionally include one or more mill charge media sensor elements, such as the mill charge media sensor elements 140 depicted in
In various aspects, the mill charge media sensor elements can comprise and/or be equipped with any number of sensors for detecting one or more events or the environment in the comminution mill grinding compartment, and can be adapted to communicate such information to one or more shell sensor assemblies. In certain aspects, the mill charge media sensor elements can communicate or transmit, e.g., to one or more shell sensor assemblies, information associated with RFID data, accelerometer G-Force data, accelerometer spin data, temperature data, or a combination thereof. At a high level, the mill charge media sensor elements can include a sensor component and a housing.
The battery 314 can be any type of battery that is suitable for use in the sensor component 300 and/or in the systems and methods disclosed herein. In various aspects, the battery 314 can include a lithium cell battery, e.g., a lithium cell coin battery or the like. A cushioning element 311 can be positioned around the battery 314 and/or adjacent the one or more sensors 308. In various aspects, the cushioning element 311 can be any suitable cushioning material, such as, for example, a polymeric foam composition and/or a low-density polymeric foam composition.
In various aspects, the one or more sensors 308 can include a temperature sensor, an accelerometer sensor, a gyroscope, a magnetic sensor, a gyroscope, a capacitive sensor, a microphone, an RFID sensor, any other sensor that can measure rotation or spin, or a combination thereof. Any types of specific sensors can be included that are suitable for use in the sensor component 300 and/or in the systems and methods disclosed herein. In various aspects, the one or more sensors 308 can be coupled to a printed circuit board along with one or more processors.
In various aspects, the antenna 302 can include a metal material. In one aspect, the antenna 302 can include a copper beryllium alloy. In certain aspects, at least a portion of the antenna 302 can form a helical structure.
In various aspects, the sensor component 300 can include a bottom cushioning material 310, e.g., a silicone material. In the same or alternative aspects, a potting material 306 can be present that fills in around one or more of the sensors 308 and/or the printed circuit board 316 and/or the battery 314. The potting material 306 can include any polymeric material, such as, for example, a silicone, polyurethane, resin, epoxy, or other elastomeric material. A similar or different potting material 304 can be used to fill in around the antenna 302.
In certain aspects, optionally, a disc or ring 312, which can comprise a metal, such as steel, can be positioned inside the sensor component 300 to create a bottom chamber comprising the battery 314, the one or more sensors 308 and the printed circuit board 316; and a top chamber comprising the antenna 302. In the aspect depicted in
In various aspects, not depicted in
As discussed above, in aspects, the mill charge media sensor elements and/or the sensor component 300 can communicate data obtained from onboard sensors to one or more of the shell sensor assemblies, which can then, in turn, communicate this information to a receiver, e.g., the receiver 130. The mill charge media sensor element and/or the sensor component 300 can relay the sensed data to the shell sensor assembly using any convenient wireless communication technology, including but not limited to WiFi, Near-field communication (NFC), Bluetooth, and the like.
As can be seen in
In the aspect depicted in
It should be understood that the specific shapes and sizes of the housings, and of the shape, position, size, and number of sensor components in the mill charge media sensor elements 320 and 330 of
As discussed above, in certain aspects, the shell sensor assemblies can be spaced apart from one another and can provide a plurality of mill interior measurement zones. In aspects, any number of mill interior measurement zones can be provided. In one aspect, the plurality of mill interior measurement zones can include at least two, at least three, at least four, or at least five mill interior measurement zones.
As can be seen in
In the aspect depicted in
In one or more aspects, the mill interior measurement zone 411a can extend from the feed end 412 to, generally, the dashed line 413a. The mill interior measurement zone 411a can include the shell sensor assembly 410a, which can provide sensor measurements for this mill interior measurement zone 411a. In one or more aspects, the mill interior measurement zone 411b can extend between the dashed lines 413a and 413b. The mill interior measurement zone 411b can include the shell sensor assembly 410b, which can provide sensor measurements for this zone. In one or more aspects, the mill interior measurement zone 411c can extend between the dashed lines 413b and 413c. The mill interior measurement zone 411c can include the shell sensor assembly 410c, which can provide sensor measurements for this zone. In one or more aspects, the mill interior measurement zone 411d can extend between the dashed lines 413c and 413d. The mill interior measurement zone 411d can include the shell sensor assembly 410d, which can provide sensor measurements for this zone. In one or more aspects, the mill interior measurement zone 411e can extend between the dashed line 413d to the discharge end 414. The mill interior measurement zone 411e can include the shell sensor assembly 410e, which can provide sensor measurements for this zone. In aspects, the mill interior measurement zones 411a, 411b, 411c, 411d, and 411e can be axial measurement zones, e.g., zones that extend along an axis that extends between the feed end 412 and the discharge end 414 of the comminution mill 400.
In aspects, as discussed above, mill charge media sensor elements can optionally be present in the interior of the mill, e.g., the comminution mill grinding compartment. As also discussed above, in aspects, the mill charge media sensor elements can communicate data obtained from onboard sensors to one or more of the shell sensor assemblies, which can then, in turn, communicate this information to a receiver, e.g., the receiver 130. In aspects, mill charge media sensor elements that are within a zone of detection of an individual shell sensor assembly can relay the sensed data to that shell sensor assembly.
In various aspects, the shell sensor assemblies can be adapted to receive sensed data from a mill charge media sensor element and/or detect the proximate presence of a mill charge media sensor element when the mill charge media sensor element is within about 150 centimeters (cm), within about 100 cm, within about 75 cm, within about 50 cm, or within about 30 cm of the shell sensor assembly and/or of a receiving antenna of the shell sensor assembly. In various aspects, the range with which a shell sensor assembly can receive sensed data from a mill charge media sensor and/or detect the presence of the mill charge media sensor can also be referred to as a zone of detection and/or an axial zone of detection. As can be seen in
It should also be understood that while the comminution mill 400 depicted herein only depicts one shell sensor assembly per mill interior measurement zone, any number of shell sensor assemblies can be present in a mill interior measurement zone. For instance, in an aspect depicted in
In the aspect depicted in
In certain aspects, the shell sensor assemblies can receive data broadcast or transmitted from the mill charge media sensor elements continually or at various intervals. In aspects wherein the shell sensor assemblies receive data broadcast or transmitted from the mill charge media sensor elements at various intervals, the intervals can be process related. For example, in certain aspects, the shell sensor assemblies can receive data broadcast or transmitted from the mill charge media sensor elements based on an absolute and/or specific position of the shell sensor assembly.
In the example aspect of
In the example aspect of
In the example aspect of
It should be understood that while in the example aspects depicted in
In aspects wherein the shell sensor assemblies receive data broadcast or transmitted from the mill charge media sensor elements at various intervals, the intervals can be time related. In such aspects, the shell sensor assemblies can communicate the sensed data, process data, or both from the shell sensor assemblies, and/or the sensed data, process data, or both received from the mill charge media sensor elements at specific time intervals, such as, for example, every 0.1 seconds, every 0.5 seconds, every second, every 5 seconds, every 10 seconds, every 30 seconds, or every minute.
In certain aspects, as discussed above, the shell sensor assemblies can detect absolute position, e.g., with respect to the rotational position of the comminution mill grinding compartment. In the same or alternative aspects not depicted in the figures, the comminution mill sensor systems disclosed herein can include a calibration reference point, e.g., a magnetic calibration reference point. In such aspects, when a shell sensor assembly passes the calibration reference point, the shell sensor assembly can re-zero or otherwise calibrate the sensor absolute position, e.g., using a magnetic sensor onboard the shell sensor assembly.
As can be seen in
In various aspects, as discussed above, the shell sensor assemblies can transmit or communicate the process data and/or sensed data (from the shell sensor assemblies and/or the mill charge media sensor elements) to a receiver, e.g., the receiver 130. As used herein, a receiver is broadly described and can include, not only a component for receiving the process data and/or sensed data communicated by the shell sensor assemblies, but also other computing device components for processing the received data, e.g., to generate two-dimensional process maps and/or three-dimensional process maps.
In certain aspects, implementations of the present disclosure may be practiced in a variety of system configurations, including handheld devices, consumer electronics, general-purpose computers, specialty computing devices, etc. Implementations of the present disclosure may also be practiced in distributed computing environments where tasks are performed by remote-processing devices that are linked through a network.
With continued reference to
The computing device 700 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computing device 700 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules or other data.
Computer storage media includes RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices. Computer storage media does not comprise a propagated data signal.
Communication media typically embodies computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer-readable media.
The memory 704 includes computer-storage media in the form of volatile and/or nonvolatile memory. The memory 704 may be removable, nonremovable, or a combination thereof. Exemplary memory includes solid-state memory, hard drives, optical-disc drives, etc. The computing device 700 includes one or more processors 706 that read data from various entities such as bus 702, the memory 704 or the I/O components 712. One or more presentation components 708 presents data indications to a person or other device, in aspects. Exemplary one or more presentation components 708 include a display device, speaker, printing component, vibrating component, etc. The I/O ports 710 allow the computing device 700 to be logically coupled to other devices including the I/O components 712, some of which may be built in the computing device 700. Illustrative I/O components 712 include a receiver for receiving communications, microphone, joystick, game pad, satellite dish, scanner, printer, wireless device, etc. In aspects, the receiver can use any type of wired or wireless communication protocols including Bluetooth, Wi-Fi, NFC, wireless telecommunication protocols, e.g., 3G, 4G, 5G, etc.
The radio 716 represents a component that facilitates wireless communication, in aspects. Illustrative wireless communication technologies include Wi-Fi, 3G, 4G, 5G, Bluetooth, NFC, VoIP, and the like.
In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one pulp slurry zone of a mill charge within the mill grinding compartment. In certain aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one cascade crushing zone of a mill charge within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one impact toe angle of a mill charge within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one bulk toe angle within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one cascade abrasion zone within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one locked charge zone within the mill grinding compartment. In certain aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one departure zone within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one shoulder angle within the mill grinding compartment. In one or more aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one head angle within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one dead zone within the mill grinding compartment. In various aspects, the receiver or other computing device or component can be configured to receive sensor data indicative of at least one cataract zone within the mill grinding compartment.
In aspects, as discussed above, one or more the shell sensor assemblies can communicate to a receiver the sensed data, process data, or both from the shell sensor assemblies, and/or the sensed data, process data, or both received from the mill charge media sensor elements. The receiver and/or other computing device may be configured to construct a two-dimensional process map of the mill, a three-dimensional process map of the mill, or both, based on sensed data, process data, or both from the shell sensor assemblies, and/or the sensed data, process data, or both received from the mill charge media sensor elements. Further, in one or more aspects, the receiver and/or other computing device may be configured to calculate at least one trajectory of at least a portion of a mill charge, a mill charge media sensor element, or both based on sensed data, process data, or both from the shell sensor assemblies, and/or the sensed data, process data, or both received from the mill charge media sensor elements.
In certain aspects, the two-dimensional process map and/or the three-dimensional process map can include any or all of the sensed data or process data from the shell sensor assemblies and/or the mill charge media sensor elements. In various aspects, the two-dimensional process map and/or the three-dimensional process map can include a depiction of an axial flow profile of the mill charge and/or of one or more mill charge media sensor elements. In aspects, the axial flow profile can include a trend line and/or depiction of one or more mill charge feature or zone in various axial measurement zones, e.g., to provide an axial flow profile of the mill charge between the feed end and discharge end of the comminution mill grinding compartment. In one or more aspects, the two-dimensional process map and/or the three-dimensional process map can depict a profile and/or trend line of a position of a head angle, bulk toe angle, or other mill charge feature or zone in a plurality of adjacent axial measurement zones extending from a feed end to a discharge end of a comminution mill grinding compartment. In various aspects, the receiver and/or other computing device can link radial measurement zone data, e.g., shoulder angles, head angles, bulk charges, toe angles, impact data, and/or impact charge toe angle across the axial mill measurement zones, e.g., the feed end zone, the feed end middle zone, middle zone, discharge end middle zone, and the discharge end zone to provide a process map depicting the axial flow of the mill charge.
In one or more aspects, the two-dimensional process map and/or the three-dimensional process map can include one or more parameters calculated or estimated by the receiver and/or another computing device. For instance, in certain aspects, a calculated or estimated trajectory for at least a portion of the mill charge and/or of one or more mill charge media sensor elements can be included in a two-dimensional process map and/or the three-dimensional process map. In the same or alternative aspects, the receiver and/or other computing device can utilize the sensed data to calculate a mill charge volume. It should be understood that other calculations may be determined and/or performed by the receiver and/or other computing device, including calculations completed by shell sensor assemblies and/or a mill charge media sensor elements. A non-limiting list of calculations and/or estimations based on the sensed data can include trajectory of an object, mill charge volume, spin rate of an object, and angular speed of an object.
In certain aspects, as discussed above, the shell sensor assemblies are adapted to receive sensed data and/or process data from one or more mill charge media sensor elements. In such aspects, the shell sensor assemblies can communicate the sensed data, process data, or both from the shell sensor assemblies, and/or the sensed data, process data, or both received from the mill charge media sensor elements to the receiver. The sensed data and/or process data from the mill charge media sensor elements can include any or all of the properties and/or parameters disclosed herein.
The method 800 also includes the step 820 of determining a two-dimensional process map, a three-dimensional process map, or both based on the sensing data. In one or more aspects, a receiver can perform all or a portion of the step 820. As discussed above, the receivers disclosed herein can not only include a component for receiving data from a plurality of shell sensor assemblies but can also include any type of computing device and/or computing device components.
In various aspects, a two-dimensional process map can be based on sensed data from the plurality of shell sensor assemblies, sensed data from the mill charge media sensor elements, or both. In the same or alternative aspects, a three-dimensional process map can be based on sensed data from the plurality of shell sensor assemblies, sensed data from the mill charge media sensor elements, or both. In certain aspects, the two-dimensional process map may include sensed data from one or more mill interior measurement zones, as discussed above. For instance, in one or more aspects, the two-dimensional process map may include sensed data from one or more axial measurement zones or one or more radial measurement zones. In various aspects, the three-dimensional process map can include sensed data from one or more mill interior measurement zones, as discussed above. For instance, in one or more aspects, the three-dimensional process map may include sensed data from one or more axial measurement zones and one or more radial measurement zones.
As discussed above, in certain aspects, the two-dimensional process map and/or the three-dimensional process map can include any or all of the sensed data or process data from the shell sensor assemblies and/or the mill charge media sensor elements. For example, as discussed above, the two-dimensional process map and/or the three-dimensional process map can include a trend line and/or depiction of the one or more mill charge feature or zone in various axial measurement zones, e.g., to provide an axial flow profile of the mill charge. For instance, in certain aspects, a two-dimensional process map and/or a three-dimensional process map can depict a profile and/or trend line of a position of a head angle, bulk toe angle, or other mill charge feature or zone in a plurality adjacent axial measurement zones extending from a feed end to a discharge end of a comminution compartment. As discussed above, the receiver or other computing component can link radial measurement zone data, e.g., shoulder angles, head angles, bulk charges, toe angles, impact data, and/or impact charge toe angle across the axial mill measurement zones, e.g., the feed end zone, the feed end middle zone, middle zone, discharge end middle zone, and the discharge end zone to provide a process map depicting the axial flow of the mill charge.
In certain aspects, the two-dimensional process map and/or the three-dimensional process map can include one or more parameters calculated or estimated by the receiver and/or another computing device. For instance, in certain aspects, a calculated or estimated trajectory for at least a portion of the mill charge and/or of one or more mill charge media sensor elements can be included in a two-dimensional process map and/or the three-dimensional process map. In the same or alternative aspects, the receiver and/or other computing device can utilize the data for an axial flow process map to calculate the mill charge volume.
In various aspects, the method 800 can also include displaying one or more two-dimensional process map, one or more three-dimensional process map or both. In certain aspects, the method 800 can also include providing an indication that based on the sensed data and/or one or more two-dimensional process map, one or more three-dimensional process map, or both, to adjust the mill charge feed rate or other comminution mill parameter to optimize the comminution operation.
The present disclosure can be described in accordance with the following numbered clauses.
Clause 1. A comminution mill sensor system, comprising: a plurality of shell sensor assemblies, wherein each of the plurality of shell sensor assemblies comprises: at least one sensor or sensor array, at least one energy source, and at least one antenna, wherein each of the plurality of shell sensor assemblies is coupled to a comminution mill grinding compartment, and wherein the plurality of shell sensor assemblies are adapted to provide for a plurality of mill interior measurement zones within the comminution mill grinding compartment.
Clause 2. The comminution mill sensor system according to clause 1, wherein each of the plurality of shell sensor assemblies is spaced apart so as to provide the plurality of mill interior measurement zones.
Clause 3. The comminution mill sensor system according to clauses 1 or 2, wherein the plurality of mill interior measurement zones comprise at least two axial measurement zones.
Clause 4. The comminution mill sensor system according to clause 3, wherein the plurality of mill interior measurement zones further comprise at least four radial measurement zones.
Clause 5. The comminution mill sensor system according to clauses 3 or 4, wherein the at least two axial measurement zones are located between a feed end of the comminution mill grinding compartment and a discharge end of the comminution mill grinding compartment.
Clause 6. The comminution mill sensor system according to any of clauses 3-5, wherein the at least two axial measurement zones comprise a substantially equal arrangement of zones distributed along substantially a length of the comminution mill grinding compartment.
Clause 7. The comminution mill sensor system according to any of clauses 4-6, wherein the at least four radial measurement zones comprise zones within a cross-section of the comminution mill grinding compartment, the zones comprising: a first radial zone including an open portion of a mill charge; a second radial zone including a toe portion of a mill charge; a third radial zone including a kidney portion of a mill charge; and a fourth radial zone including a shoulder portion of a mill charge.
Clause 8. The comminution mill sensor system according to any of clauses 1-7, wherein the at least one sensor or sensor array is operable to communicate sensor data wirelessly via the at least one antenna to at least one receiver positioned outside the comminution mill grinding compartment.
Clause 9. The comminution mill sensor system according to clause 8, wherein the at least one receiver is configured to receive sensor data indicative of: at least one pulp slurry zone of a mill charge within the comminution mill grinding compartment, at least one cascade crushing zone of a mill charge within the comminution mill grinding compartment, at least one impact charge toe angle of a mill charge within the comminution mill grinding compartment, at least one bulk charge toe angle of a mill charge within the comminution mill grinding compartment, at least one cascade abrasion zone of a mill charge within the comminution mill grinding compartment, at least one locked charge zone of a mill charge within the comminution mill grinding compartment, at least one departure zone of a mill charge within the comminution mill grinding compartment, at least one shoulder angle of a mill charge within the comminution mill grinding compartment, at least one head angle of a mill charge within the comminution mill grinding compartment, at least one dead zone of a mill charge within the comminution mill grinding compartment, at least one cataract zone of a mill charge within the comminution mill grinding compartment, or a combination thereof.
Clause 10. The comminution mill sensor system according to any of clauses 1-9, wherein the at least one sensor or sensor array comprises at least one Radio Frequency Identification (RFID) sensor, at least one inertial measurement unit (IMU), wherein the IMU comprises at least an accelerometer sensor and a gyroscope sensor, at least one magnetic sensor, at least one absolute position sensor, at least one angular speed sensor, at least one impact sensor, or a combination thereof.
Clause 11. The comminution mill sensor system according to any of clauses 1-10, wherein at least a portion of the plurality of shell sensor assemblies are configured to sense impact data, sense absolute position, sense absolute position of impact data, or a combination thereof.
Clause 12. The comminution mill sensor system according to any of clauses 1-11, further including a plurality of mill charge media sensor elements positioned within the comminution mill grinding compartment, each of the mill charge media sensor elements equipped with at least one energy source, at least one antenna, at least one RFID sensor, at least one accelerometer sensor at least one temperature sensor, or a combination thereof.
Clause 13. The comminution mill sensor system according to clause 12, wherein the plurality of mill charge media sensor elements is operable to wirelessly communicate RFID data, accelerometer data, temperature data, or a combination thereof, to at least one of the plurality of shell sensor assemblies while the plurality of mill charge media sensor elements are within a zone of detection of a shell sensor assembly of the plurality of shell sensor assemblies.
Clause 14. The comminution mill sensor system according to clause 8, wherein each of the plurality of shell sensor assemblies is configured for receiving process data from within the comminution mill grinding compartment and transmitting the process data to the at least one receiver.
Clause 15. The comminution mill sensor system according to any of clauses 1-14, wherein the plurality of shell sensor assemblies are configured to receive RFID data, accelerometer G-Force data, accelerometer spin data, temperature data, or a combination thereof, from one or more mill charge media sensor elements.
Clause 16. The comminution mill sensor system according to any of clauses 1-15, wherein each shell sensor assembly of the plurality of shell sensor assemblies is configured with a data relay mode to receive data broadcast from one or more mill charge media sensor elements while the one or more mill charge media sensor elements are within an axial zone of detection.
Clause 17. The comminution mill sensor system according to clause 16, wherein an association of the shell sensor assembly data, proximate mill charge media sensor element data, and optionally absolute position data, provides an indication of an axial zone location of a mill charge media sensor element of the one or more mill charge media sensor elements.
Clause 18. The comminution mill sensor system according to clause 12, wherein at least one shell sensor assembly of the plurality of shell sensor assemblies is operable to detect a mill charge media sensor element of the plurality of mill charge media sensor elements positioned within about 150 centimeters (cm) or less proximate to the at least one shell sensor assembly and/or to the at least one antenna of the at least one shell sensor assembly.
Clause 19. The comminution mill sensor system according to clause 12, wherein each of the plurality of shell sensor assemblies is configured to relay data from one or more mill charge media sensor elements to at least one receiver positioned outside the comminution mill grinding compartment.
Clause 20. The comminution mill sensor system according to clause 19, wherein the at least one receiver is configured to construct a three-dimensional process map of the comminution mill grinding compartment based on data from the plurality of mill charge media sensor elements, data from the plurality of shell sensor assemblies, or both.
Clause 21. The comminution mill sensor system according to clause 19, wherein the at least one receiver is configured to calculate at least one trajectory of at least one mill charge media sensor element of the plurality of mill charge media sensor elements based on data from the at least one mill charge media sensor element, data from at least one shell sensor assembly of the plurality of shell sensor assemblies, or both.
Clause 22. The comminution mill sensor system according to any of clauses 1-21, wherein for each of the plurality of shell sensor assemblies, the at least one antenna extends through a shell of the comminution mill grinding compartment.
Clause 23. The comminution mill sensor system according to any of clauses 1-22 further comprising a processor communicatively coupled with a receiver, wherein the receiver is configured to receive mill charge media sensor element data, shell sensor assembly data, or both.
Clause 24. The comminution mill sensor system according to any of clauses 1-23, wherein each of the plurality of shell sensor assemblies is coupled to a shell associated with the comminution mill grinding compartment, a shell liner associated with the comminution grinding compartment, a liner bolt associated with the comminution grinding compartment, or a combination thereof.
Clause 25. The comminution mill sensor system according to any of clauses 1-24, wherein at least a portion of the plurality of shell sensor assemblies is coupled to an exterior portion of the comminution mill grinding compartment.
Clause 26. The comminution mill sensor system according to any of clauses 1-25, wherein at least a portion of the plurality of shell sensor assemblies is coupled to an interior portion of the comminution mill grinding compartment.
Clause 27. The comminution mill sensor system according to any of clauses 1-26, wherein each of plurality of shell sensor assemblies is coupled to an interior portion of the comminution mill grinding compartment and/or to an exterior portion of the comminution mill grinding compartment.
Clause 28. A method for monitoring comminution mill operation conditions, comprising: receiving sensing data from a plurality of shell sensor assemblies during operation of a comminution mill, wherein each of the plurality of shell sensor assemblies comprise at least one sensor or sensor array, at least one energy source, and at least one antenna, and wherein each of the plurality of shell sensor assemblies is coupled to a comminution mill grinding compartment of the comminution mill, at spaced apart positions so as to provide a plurality of mill interior measurement zones; and determining a two-dimensional process map, a three-dimensional process map, or both, based on the sensing data.
Clause 29. The method according to clause 28, wherein the receiving sensing data comprises transmitting the sensing data from the plurality of shell sensor assemblies to one or more receivers positioned outside of an interior of the comminution mill grinding compartment.
Clause 30. The method according to clauses 28 or 29, wherein the sensing data comprises data associated with: at least one pulp slurry zone of a mill charge within the comminution mill grinding compartment, at least one cascade crushing zone of a mill charge within the comminution mill grinding compartment, at least one impact charge toe angle of a mill charge within the comminution mill grinding compartment, at least one bulk charge toe angle of a mill charge within the comminution mill grinding compartment, at least one cascade abrasion zone of a mill charge within the comminution mill grinding compartment, at least one locked charge zone of a mill charge within the comminution mill grinding compartment, at least one departure zone of a mill charge within the comminution mill grinding compartment, at least one shoulder angle of a mill charge within the comminution mill grinding compartment, at least one head angle of a mill charge within the comminution mill grinding compartment, at least one dead zone of a mill charge within the comminution mill grinding compartment, at least one cataract zone of a mill charge within the comminution mill grinding compartment, or a combination thereof.
Clause 31. The method according to any of clauses 28-30, wherein the sensing data comprises impact data, absolute position data, absolute position of impact data, or a combination thereof.
Clause 32. The method according to any of clauses 28-31, wherein the plurality of mill interior measurement zones comprise at least two axial measurement zones.
Clause 33. The method according to any of clauses 28-32, wherein the at least two axial measurement zones are located between the feed end of the comminution mill grinding compartment and the discharge end of the comminution mill grinding compartment.
Clause 34. The method according to any of clauses 28-33, wherein the plurality of mill interior measurement zones comprise at least four radial measurement zones, wherein the at least four radial measurement zones comprise zones within a cross-section of the comminution mill grinding compartment.
Clause 35. The method according to clause 34, wherein the zones within the cross-section of the comminution mill grinding compartment comprise: a first radial zone including an open portion of a mill charge; a second radial zone including a toe portion of a mill charge; a third radial zone including a kidney portion of a mill charge; and a fourth radial zone including a shoulder portion of a mill charge.
Clause 36. The method according to any of clauses 28-35, wherein the receiving sensing data comprises receiving sensing data wirelessly via the at least one antenna of each of the plurality of shell sensor assemblies, to a receiver positioned outside the comminution mill grinding compartment.
Clause 37. The method according to any of clauses 28-36, wherein the sensing data comprises sensing data from one or more mill charge media sensor elements positioned within the interior of the comminution mill grinding compartment.
Clause 38. The method according to clause 37, wherein each of the one or more mill charge media sensor elements are equipped with at least one energy source, at least one antenna, at least one RFID sensor, at least one accelerometer sensor, at least one temperature sensor, or a combination thereof.
Clause 39. The method according to clause 37 or 38, wherein each of the one or more mill charge media sensor elements is operable to wirelessly communicate RFID data, accelerometer data, temperature data, or a combination thereof, to at least one of the plurality of shell sensor assemblies while the one or more mill charge media sensor elements are within a zone of detection of the at least one of the plurality of shell sensor assemblies.
Clause 40. The method according to any of clauses 37-39, wherein the plurality of shell sensor assemblies are configured to receive RFID data, accelerometer G-Force data, accelerometer spin data, temperature data, or a combination thereof from the one or more mill charge media sensor elements.
Clause 41. The method according to any of clauses 37-40, wherein each shell sensor assembly of the plurality of shell sensor assemblies is configured with a data relay mode to receive data broadcast from the one or more mill charge media sensor elements while the one or more mill charge media sensor elements are within an axial zone of detection.
Clause 42. The method according to any of clauses 37-41, wherein an association of the shell sensor assembly data, proximate mill charge media sensor element data, and optionally absolute position data, provides an indication of an axial zone location of a grinding media element of the one or more mill charge media sensor elements.
Clause 43. The method according to any of clauses 37-42, wherein at least one shell sensor assembly of the plurality of shell sensor assemblies detects a mill charge media sensor element positioned within about 500 millimeters or less proximate to the at least one shell sensor assembly.
Clause 44. The method according to any of clauses 37-43, wherein each of the plurality of shell sensor assemblies relays data from the one or more mill charge media sensor elements to at least one receiver positioned outside of the mill grinding compartment.
Clause 45. The method according to any of clauses 37-44, wherein the determining the two-dimensional process map, the three-dimensional process map, or both comprises determining the two-dimensional process map, the three-dimensional process map, or both, based on: the sensed data from the plurality of shell sensor assemblies; data from the one or more mill charge media sensor elements; or both.
Clause 46. The method according to any of clauses 37-45, further comprising calculating a trajectory of at least one mill charge media sensor element of the one or more mill charge media sensor elements based on: the sensed data from the plurality of shell sensor assemblies; data from the one or more mill charge media sensor elements; or both.
Clause 47. The comminution mill sensor system according to any of clauses 28-46, wherein each of the plurality of shell sensor assemblies is coupled to a shell associated with the comminution mill grinding compartment, a shell liner associated with the comminution grinding compartment, a liner bolt associated with the comminution grinding compartment, or a combination thereof.
Clause 48. The comminution mill sensor system according to any of clauses 28-47, wherein at least a portion of the plurality of shell sensor assemblies is coupled to an exterior portion of the comminution mill grinding compartment.
Clause 49. The comminution mill sensor system according to any of clauses 28-48, wherein at least a portion of the plurality of shell sensor assemblies is coupled to an interior portion of the comminution mill grinding compartment.
Clause 50. The comminution mill sensor system according to any of clauses 28-49, wherein each of the plurality of shell sensor assemblies is coupled to an interior portion of the comminution mill grinding compartment and/or to an exterior portion of the comminution mill grinding compartment.
Clause 51. A comminution mill sensor system for calculating the trajectory of at least one mill charge media sensor element within a comminution mill compartment, the comminution mill sensor system comprising: at least one shell sensor assembly, the at least one shell sensor assembly comprising: at least one energy source; at least one sensor array situated inside the at least one shell sensor assembly, wherein the at least one sensor array is configured to detect information at least indicative of a time-indexed presence of the at least one mill charge media sensor element within at least one zone of detection within at least one measurement zone corresponding to a portion of the comminution mill compartment; a processor operably coupled with a memory configured for storing instructions that when executed configure the processor to calculate at least one trajectory information value from the information at least indicative of a time-indexed presence of the at least one mill charge media sensor element within the at least one zone of detection, the memory further configured to at least temporarily store the trajectory information value of the mill charge media sensor element; and at least one antenna connected to the at least one sensor array.
Clause 52. The comminution mill sensor system according to clause 51, wherein the processor is positioned within the at least one shell sensor assembly, the at least one mill charge media sensor element, or outside of the comminution mill compartment.
Clause 53. The comminution mill sensor system of clauses 51 or 52, wherein the at least one measurement zone comprises a two-dimensional data set, the two-dimensional data set being indicative of a radial zone of detection or an axial zone of detection within the comminution mill compartment.
Clause 54. The comminution mill sensor system of any of clauses 51-53, wherein the at least one measurement zone comprises a three-dimensional data set, the three-dimensional data set being indicative of a radial zone of detection and an axial zone of detection within the comminution mill compartment.
Clause 55. A comminution mill sensor system comprising: at least one array of shell sensors distributed around a comminution mill compartment, the array of shell sensors configured to sense location and motion data from a plurality of mill charge media sensor elements, wherein the at least one array of shell sensors is configured to define a set of detection zones arranged both radially and axially within the comminution mill compartment; and at least one processor configured to compute trajectory data based on location and motion data received from at least a portion of the at least one array of shell sensors, the plurality of mill charge media elements, or both.
Clause 56. A method for computing comminution mill grinding media trajectory comprising: sensing location and motion data from a plurality of mill charge media sensor elements at an array of shell sensor assemblies; calculating mill charge media sensor element position within a mill grinding compartment in real-time; computing trajectory data based on real-time mill charge media element position calculations; and transmitting the trajectory data to a remote receiver.
Clause 57. The method of clause 48, wherein the real-time mill charge media element position calculations are performed by an edge processor positioned at a hub proximate to at least one receiver situated outside the mill grinding compartment.
This disclosure has been described in detail with particular reference to specific aspects thereof, but it will be understood that variations and modifications can be made within the spirit and scope of this disclosure.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2021/059874 | 11/18/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63115480 | Nov 2020 | US |
