OreVia Slurry

The OreVia Slurry application is an advanced system that accurately detects fine particle sizes in various locations in the concentrator plant and provides high-resolution fines analysis and delivers fast, real-time particle measurements.

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Features

  • Measures particle size of slurry in various locations in the concentrator plant in the ranges 1–200 µm and 10 – 1100 µm
  • AI system learns and improves over time
  • Offers high-resolution fines analysis
  • Detects and adapts to ore variations
  • Integrates with control systems and the Molycop VIP Platform
  • Permissible process temperature: -10 – 130°C (temperatures up to 450°C achievable with cooling tube accessory)
  • 5.1 MP Machine Vision Camera with GigE Interface, 15 fps

Overview

OreVia detects fine particle size and fragmentation in pipes, adapts to variability in particle size, and provides real-time high-resolution fines analysis and particle size measurements, without the need to sub sample. 

The technology consists of a high-resolution endoscope installed directly into a slurry pipe to retrieve particle size and shape information via image analysis. Only one endoscope is provided, and the measurement range will be determined in collaboration with the client to best suit their needs. Typical measurement ranges are: 
  • 1–200 µm for fine particles.
  • 10–1100 µm for coarser particles.
The system works by identifying the outline of fine particles in the crusher process discharge stream using AI-powered technology. It then calculates rock size based on the best-fitting ellipse for each rock. The outcome is a Particle Size Distribution (PSD) that measures the fragmentation of the ore.

The system offers remote monitoring and playback features and integrates seamlessly with existing control systems. OreVia can easily be evaluated off-site through quick image-based demonstrations provided by Molycop using client slurry samples.

Real-time fragmentation control

Artificial Intelligence has paved the way for robust, affordable and accurate particle-size insights. 

Measurements from the cyclones (either cyclone feed or cyclone overflow) are helpful in ensuring optimal operation. For most plants, the mill P80 is a typical measurement as it significantly affects the mill and overall plant operation. Control systems can use this measurement to adjust the mill operation based on the particle size of the ore discharged. This measurement can be used to understand the effects of changing ore characteristics, milling density, mill feed rate, etc. It can also be used to tune the performance of the cyclones themselves.

Data is continuously collected in real time and securely stored in a time-series database, ensuring a comprehensive record of process performance. This structured data allows for easy retrieval, trend analysis and in-depth evaluations, enabling operators to monitor changes over time, identify patterns and make informed decisions to optimise efficiency and performance.

With deep expertise in control solutions, Molycop seamlessly integrates OreVia into control systems to enhance operational efficiency. Designed for compatibility with Molycop’s advanced optimisation suite, including MillSlicer and MillStar APC, this solution ensures precise mill performance and process control.

Typical Uses

OreVia is primarily used by mining operations to improve mill operation and productivity. The system provides real-time data on fine particle size, which is then used to optimise stages of the mineral processing circuit, from crushing through to flotation or leaching. For mineral processing plants, it is crucial to understand what particle size is being delivered downstream for ore liberation.

An alternate application is on the feed or discharge of slurry thickeners. For example, for discharge applications, this can be particularly useful to understand the effects of particle size on slurry shear stresses for pumping of concentrates to a distant port prior to dewatering.

Benefits

  • Real-time optimisation: Real-time data enables operators to make immediate adjustments to the milling circuit to maintain optimal particle size.
  • Increased throughput: Improved process control with real-time adjustments, especially using an APC system, for optimal mill control delivers improved mill throughput and product specification consistency (system will emit an alarm if material is out of specification).
  • Increased profitability: With reduced mill operation costs and improved energy consumption, along with improved throughput and product specification consistency, OreVia delivers real-world profitability improvement.

Related Products & Services

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