COMMINUTION
Molycop ’ s flowsheet touchpoints
Molycop has a reputation as an R & D leader in the grinding space , with much of the mineral processing community keeping close tabs on its research . IM put some questions to Paul Shelley , VP Innovation , about how this research fits into the wider Molycop strategy .
IM : How are you allocating your R & D budgets when it comes to optimising & refining existing processes within the traditional SABC circuit and investing in projects looking at alternatives ? PS : Molycop ’ s core product is grinding media . In the mineral processing circuit of hard-rock ores , grinding media is a significant cost to established processing circuits and an influence on processing optimisation . It has several touchpoints within the revenue and cost flowsheet of a concentrator . These include an influence on throughput , recovery , efficient comminution energy use , customer carbon footprint , media price and media consumption .
Molycop has three platforms to accelerate the development of media : modelling and simulation , new-to-industry testing and benching technology and alloy research with world renowned experts . Taking each in turn . Molycop has utilised artificial intelligence and machine learning to build simulators that consider mineral characteristics , mill dynamics and product metallurgy . These manifest as two platforms : ball consumption modelling and prediction , and a mill family model . The models use data to group mills into clusters of families . The families share mineral and mill dynamics characteristics and allow for product metallurgy to be designed as a best fit for the tumbling mill . Ball consumption prediction is valuable as a unique output and also contributes to the operating input of the mill family model . Modelling and scenario analysis is fast , allowing for quick decision making of alloy design .
Enhancing Molycop ’ s alloy design capabilities are research agreements with leading universities and researchers . A good example is the PhD project at Queen Mary University of London ( QMUL ). The three-year research partnership between Molycop and QMUL uses materials design and process simulations to understand metallurgical processes and , hence , improve grinding media . Outcomes from the project will inform the mining industry on optimum process conditions and provide guidance on what alloy compositions are best suited to grinding media . Once a new alloy is designed it must be tested and benchmarked fast .
Dr Paul Shelley , VP Innovation for Molycop
Currently the industry uses the Marked Ball Wear Test ( MBWT ) as the method for benchmarking and evaluating media . The difficulties in the time , logistics , low retrieval rates and interpretation of the MBWT results have led to the pursuit of a better test : essentially , a laboratory apparatus which can test the products in experimental conditions like service conditions and , hence , can reliably benchmark products in a time-effective manner to facilitate making decisions on good product performance . Such a test , or tests , would not replace the MBWT , but rather , make new product development and product performance interpretation faster , easier and economically more viable .
For two decades The University of Queensland ’ s Materials Performance ( UQMP ) group has been developing a laboratory test that replicates the media wear of an industrial mill , the Ball Mill Abrasion Test ( BMAT ). Their research confirmed that it is possible to obtain accurate predictions of plant wear rate from laboratory ball mill wear tests , so long as the wear rate is expressed in the appropriate terms . Molycop has a technology agreement with UQMP to build and deploy the BMAT in wear hubs around the Molycop footprint . Three machines are built with the first already operating in Chile . Decision making on alloy performance is fast and credible . A PhD research project with UQMP has the objective to use the testing equipment to understand ball chipping and impact fatigue , and thus have a laboratory process for analysing SAG ball performance .
IM : Going back to AI and ML , are you applying platforms like the Molycop Digital Engine to a variety of milling setups ? Where do you see this engine being strongest in terms of its outputs ? PS : Molycop ’ s advanced instrumentation and
cutting-edge analytics can transform AG , SAG and ball mill grinding for real-time operational excellence . At Molycop , our primary product is grinding media , and we now have the technology to monitor its performance inside the mills in real time . By way of specific example , the database from the MillSlicer VIP platform allows for validation of the ML ball consumption model . Good data is crucial to AI and ML processes . The global reach of the data generated by Molycop facilitates multi-scenario simulations for both mill family models and media consumption validation .
IM : Some OEMs are looking to provide metrics around the energy efficiency of the grinding products that their clients are choosing , which could include the embedded carbon within the balls used within mills . Are you starting to see requests from OEMs and customers for such calculations ? PS : Although we are not explicitly requested to do so by customers , we are consistently seeking to reduce the total footprint of our own operations through innovation , renewables and digital technology . By way of specific example , SAG media can be more energy intensive than ball mill media . Thus , the mill family model and alloy design work have a large role to play . We are working to develop media that has the minimum total carbon footprint without compromising the media performance .
IM : Outside of purely emission savings , where is Molycop making a significant difference to its customers ’ bottom line ( productivity , cost reductions , efficiencies , etc ) in the grinding space ? PS : The Molycop portfolio has many touchpoints in a processing circuit . We influence the revenue line via increased throughput , increased recovery and maximising grade . We influence the cost line in improving energy efficiency , reducing media wear and reducing variability . Our optimising services provide expert insight into improving these aspects . Our training portfolio improves the operating skill base and facilitates site innovation . Molycop provides process control technology for plant and equipment from crusher to recovery . In our chemicals portfolio we develop best-fit products to solve unique recovery problems .
We have embraced the digital transformation and the accelerated product development processes to make a significant contribution to our customers ’ bottom line faster and more often .
22 International Mining | MARCH 2025