Cowal Gold Operations implemented a structured, data-driven ramp-up strategy aimed at accelerating recovery to steady-state performance while maintaining mill liner integrity.
Key Facts
- The data-driven ramp-up strategy implemented at Cowal Gold Operations delivered significant production gains without compromising equipment integrity.
- Ramp-up duration at the site was cut from six weeks to four weeks and mill throughput increased by approximately 14%.
- Real-time monitoring tools MillROC and MillSlicer are critical for safely increasing operating intensity post-reline.
Cowal Gold Operations, located in New South Wales, Australia, operates a large-scale gold processing facility with a conventional comminution circuit consisting of primary crushing followed by semi-autogenous grinding (SAG) and ball milling.
Following a major mill shutdown and relining event in 2025, the site implemented a structured optimisation program to improve ramp-up efficiency without increasing operational risk. The approach incorporated controlled ball charge increases, disciplined adjustment of mill load and real-time monitoring of internal mill dynamics using MillROC and MillSlicer technologies.
The results demonstrated that ramp-up duration could be reduced from approximately six weeks to four weeks, while achieving improved throughput, increased power utilisation and enhanced operational stability. These gains were achieved without evidence of accelerated liner wear or increased risk of damage.
This case study highlights the value of a data-driven and systematic approach to ramp-up optimisation, demonstrating that significant production benefits can be realised without compromising equipment integrity.
