Global Locations

Molycop has offices in key locations all over the globe.

Executive Team

Our executive team has many years of combined experience.

History

Molycop's history spans 100 years of operation.

Molycop Worldwide

Molycop's network of manufacturing facilities, distribution centres and regional sales offices service over 400 mines across 40 countries.

StarCS

StarCS, a Mintek product distributed by Molycop, is an open, plant-wide control platform with a wide-ranging and versatile set of tools aimed at process stabilisation and optimisation.

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Features

A general control suite
Enables implementation of almost any controller
System identification and autotuning
Calculations, simulation and online estimation
Incorporates the MillStar, FloatStar and LeachStar modules
New modules are being continually developed

Overview

Distributed by Molycop, the Mintek StarCS control system is a flexible, advanced solution that optimises mineral processing operations by integrating real-time data and automated control to improve process stabilisation and optimisation.

Using the latest technology in both software and smart process control, the StarCS suite is an operator-friendly control system that seamlessly integrates various control systems, including MillStar, FloatStar and LeachStar.

Classical control

Customers have the flexibility to implement simple control on any process using the StarCS control platform, without being limited to specialised systems, allowing for easy customisation of classical controllers. The following classical controllers are available:

PID control, incorporating intelligent windup prevention at limits
Ratio control, including corrective action if the ratio setpoint cannot be achieved
Deadbeat control, model-based control calculating a control action that will ensure that the setpoint is reached within a specified time
Feed-forward control, based on user-defined process characteristics.

System identification and autotuning

Accurate model fitting and proper controller tuning are essential for optimal controller performance. Automating this process reduces commissioning time and simplifies retuning, particularly when circuit changes or other factors impact controller performance. The SID tool fits models to recorded data and calculates suggested tuning parameters, forming the foundation for customised, online autotuners tailored to specific controllers.

Typical Uses

The StarCS control suite is an open, plant-wide control platform used by mining operators and control room personnel to stabilise and optimise mineral processing operations to maximise throughput and energy efficiency.

Benefits

Open, plant-wide control platform.
Integrates all of the Molycop-distributed control systems.
Advanced process stabilisation and optimisation control.
Improves productivity.

Related Products & Services

MillStar

FloatStar

LeachStar

General Control Services

General Control Services

Related Resources

Control

Advanced control systems deliver improved outcomes for mineral processing operations.

Accelerate product development to address mining’s biggest challenges

Accelerate product development to address mining’s biggest challenges

Innovation and product development lie at the heart of a sustainable future for the mining sector, says Paul Shelley, Global Vice President of Innovation, Molycop.

Continuous improvement with MillROC support – Edikan Case Study

Continuous improvement with MillROC support – Edikan Case Study

The initial installation and set-up of MillSlicer, MillStar and MillROC at the Edikan Gold Mine in Ghana's Ashanti Gold belt was completed by April 2019. The optimisation strategy resulted in a sustainable increase in throughput of 27% in 8 months.

MillROC Improvement Project at Australian Nickel Mine

MillROC Improvement Project at Australian Nickel Mine

The objective of a MillROC improvement project at a leading Australian nickel mine was to implement a new control philosophy around the grinding circuit, which allowed for stabilisation of key operating variables. The project led to significant improvement in circuit efficiency, reduction in energy requirements and increases in throughput.

Edikan: Continuous Improvement with MillROC Support

Edikan: Continuous Improvement with MillROC Support

Molycop has successfully implemented a range of optimisation projects at the Edikan Gold Mine, including mine-to-mill optimisation, advanced instrumentation, and real-time consulting services to deliver sustainable increased throughput of 27% in 8 months.

Advanced Control

Advanced Control

In partnership with Mintek, we design, commission and implement advanced control systems to deliver improved outcomes for your mineral processing operations.

FloatStar – Flotation Control & Optimisation

FloatStar – Flotation Control & Optimisation

The FloatStar suite of control modules utilises advanced process control to overcome design-related limitations and maximise circuit performance during operation.

Innovation

At Molycop, we see innovation as a way to find solutions to some of the mining industry’s greatest challenges. We aim to improve on today so we can deliver better for tomorrow.