Molycop will participate in ALTA 2026 in Perth, Australia. Damian Thorpe, Manager – Advanced Milling Instrumentation, will present a technical paper on inline microscopy for real‑time PSD monitoring in a Brazilian iron ore operation.
Key facts
- ALTA 2026 will be held 5–7 May 2026 in Perth, Australia, bringing together global experts in mining and metallurgical processing for practical technical exchange.
- Damian Thorpe, Manager – Advanced Milling Instrumentation at Molycop, will deliver a technical presentation titled: “The implementation of an innovative inline microscope for real-time particle size distribution (PSD) monitoring in an Iron Ore processing plant in Brazil.”
- The presentation will examine how inline optical microscopy enables continuous PSD monitoring directly from the slurry stream.
Damian’s presentation focuses on the challenge faced by many iron ore operations: limited visibility of particle size in real time. Traditional manual sampling methods introduce delays that prevent PSD from being used effectively for process control. The case study demonstrates how this challenge was addressed through the installation of an inline microscope‑based analyser on the cyclone overflow.
Real-time PSD monitoring: enabling faster control and improved stability
Particle size distribution plays a critical role in mineral processing. It directly affects mineral liberation, grinding energy efficiency, cyclone performance and downstream recovery. Despite its importance, PSD is often measured infrequently and outside the process, restricting its usefulness for control decisions.Damian’s presentation demonstrates how OreVia Slurry, Molycop’s inline particle size analyser, delivers frequent and reliable PSD measurements by optically imaging slurry streams and analysing more than 10,000 particles per minute. This high‑frequency data allows operators to stabilise target grind sizes while reducing both over‑grinding and under‑grinding losses.
“As metallurgists, we talk a lot about particle size, but historically we haven’t been able to see it clearly or fast enough,” Damian explains.
Real‑time PSD measurement allows teams to move from retrospective analysis to proactive control.
Installed directly in the process, the instrument removes the need for manual sampling and provides updated PSD results approximately every five minutes, fully suitable for integration with the plant control system.
Proven performance in a Brazilian iron ore plant
The ALTA 2026 paper includes validation data comparing inline PSD results with laboratory measurements. Even using uncalibrated raw data, the system achieved a strong correlation (R² ≈ 0.85), confirming its reliability as a process monitoring tool.In addition to accuracy, the implementation delivered several operational benefits:
- Faster response to process variability
- Improved stability of the target P95 grind size
- Reduced dependence on labour‑intensive manual sampling
- Integration with the DCS and advanced process control initiatives
It’s giving operators confidence to make timely adjustments based on what’s actually happening in the circuit.
Designed for harsh operating conditions
The inline microscope system is engineered for the challenging environments typical of grinding and classification circuits. With no moving parts in contact with the slurry, low wear rates and minimal maintenance requirements, the analyser supports continuous operation across wide pressure, temperature and pH ranges.The system measures particle sizes from approximately 1 to 1200 microns and can be serviced without shutting down the process, supporting high availability and plant reliability.
Why this matters for modern grinding circuits
ALTA 2026 will explore key themes such as process digitalisation, advanced measurement, automation and data‑driven optimisation. Molycop’s contribution underscores the growing role of real‑time instrumentation in improving circuit stability and operational efficiency.“Real‑time particle size data changes what’s possible in grinding control,” Damian concludes.
It allows plants to operate closer to optimal conditions while reducing risk, energy waste and unnecessary wear.
Speak with Molycop experts at ALTA 2026
Delegates attending ALTA 2026 are encouraged to connect with Molycop’s technical specialists to learn how advanced milling instrumentation, inline sensing and process expertise combine to improve grinding circuit visibility and performance.Molycop’s focus remains on delivering practical, proven solutions that help operations convert real‑time data into measurable improvements in throughput, efficiency and sustainability.
