Automatic System for Ore Grinding Control in

Single-stage Ball Mill

T.A. Penzov, D.Z. Marinov

Innovation Firm TRAPEN, Sofia, Bulgaria
Email: [email protected]

ABSTRACT
As a result of recent scientific and experimental studies new technical devices have been devel-
oped for monitoring and control the process of grinding. The description of microprocessor mod-
ule MILLCONT 1 for control of the loading of the mill and microprocessor density control module
DENSIMETER is given in the paper. The improved variant of the automatic system for ore grinding
control in single-stage ball mill working in close cycle with a classifier with above mentioned tech-
nical means is shown in the paper. The loops for measuring and stabilization of the basic technolo-
gical parameters (density of the ready pulp ρ and fineness of grinding of the pulp β) are described in
the paper. The nowadays economic results in ore grinding process automation are given as well.

Keywords: Microprocessor module; Densimeter; System; Control loops

INTRODUCTION float with negative floatability is proportional to

the density.
The wet grinding of lead-zinc ores in Repub-
The descriptions of the new technical means
lic of Bulgaria is performed on single-stage ball
are given below as well as the improved variant
mills working in close cycle with classifier. At
of the automatic system for ore grinding control
the development of automatic system for this
in single-stage ball mill with above mentioned
type of mills and the choice of its structure the
technical means.
indirect methods for measuring of the basic
technological parameters (density of the pulp ρ NEW TECHNICAL MEANS FOR WET
and fineness of grinding β) at the outlet of the GRINDING PROCESS AUTOMATION
mill are used.
Microprocessor system MILLCONT 1
The investigation carry out on the ore mills
with the developed new microprocessor system Microprocessor system MILLCONT 1 is
MILLCONT 1 shows that impact pulses of the purposed for automation of the ore grinding
case vibration (factor of grinding FG) measur- process in the mill. The system works at opti-
ing at the mill inlet are very well correlated with mization criteria “Maximum productivity, re-
the loading (filing level) of the mill. The impact spectively minimum specific power consump-
pulses of the case vibration in the zone of pulp tion for grinding at changes of the ore qualities
formation depend on the filling level of the mill as size, hardness, grindability”. At the single-
with ore as on the density of the pulp in this stage mills working in close cycle with classifi-
zone as well. In case that the sensor is mounted er the optimal ratio sands/ready pulp at the mill
ahead the discharged grid the impact pulses are overflow is upheld according to the law of Ro-
correlated exclusively with the density of the sin-Ramler (Marinov, Penzov, 2006).
pulp at the mill outlet. The sensor of the system for remote measur-
For the control of the ready pulp at the over- ing of impact pulses SRIP (Penzov, Marinov,
flow of the classifier is developed floating den- 2005) consists of two elements, in which
simeter. The measuring elevating power by the electrical signals are generated with amplitudes

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proportional to the steepness of impact pulses at 8.2. 6-decade green display “SP/%/PAR” for
the grinding of ore. The sensor elements are indication of the set point in % and the break-
connected differential for eliminating of para- down situations in regime of operation.
sitic electromagnetic fields. The signal is trans- 8.3. 3-decade green display “OUTPUT%”
mitted through double-core armoured cable with for indication in % of control output, respec-
isolated shield. By means of special elements, tively the actuator situation;
screens, compound etc it is provided high sensi- 8.4. Line of light diods for indication of situ-
bility and selection at the measuring of impact ations at operation of the module.
pulses at distance 15~30mm. In this case the 8.5. Column of light diods for indication of
parasitic vibrations and sound signal, provoked the regimes of operation and alarms.
from near-by mills and aggregates are avoided. 8.6. Keyboard from 10 buttons for servicing
There are developed midget variants of SRIP of the module in regime of work and program-
which are used when the spot for installation is ming.
limited. 9. Terminal device for outer connection on
The microprocessor module of MILLCONT the rear part of the module, consisting 48 ter-
1 represent digital control system consisting of: minals.
1. Input differential amplifier with 10. PVC box with dimension 35mm ×
programmable gain coefficient 1, 2, 4, 8. 135mm×165mm into which are installed 3
2. Analog high frequency filter from 2nd plates: of the module, of the front panel and of
order with cutting frequency 50Hz, that the terminal device.
eleminates low frequency oscilations provoked
from mill-ovalness as well as from hatchways
and bolts closly to the measuring band.
3. Two control points after the differential
amplifier and after analog filter, which are on
the terminal device and serve for controlling of
the signal.
4. Analog amplifier of the filter signal with
gain coefficient 2.
5. 12-bit ADC.
6. Microprocessor for the signal treatment
and the forming of “factor of grinding FG”,
which is transmitted in normal or inverse type Fig. 1 Front panel of MILLCONT 1
to the input of PID-controller, to the analog
output 0(4) ~ 20mA and to the display F on the In MILLCONT 1 is inserted PID control law
front panel, in %. given with formula:
7. Microprocessor for the forming of specia- M = [Pε n + T/T i ∑ε k + T d /T (ε n −ε n−1 )]
lized PID-controller which contains the fol- 100/FG o
lowed elements: + b o [%]
7.1. Set point from the keyboard of the front where:
panel or from serial channel RS 485. The set M − output control value;
point is indicated on display SP/%/PAR in % P – gain coefficient;
7.2. Input of FG signal. ε = (SP-FG) – debalance between set point
7.3. Main current output 0(4)~20mA and two (SP) and factor of grinding (FG);
subordinated current outputs 0(4)~20mA which T – tact of the control law(PL);
are programming from the front panel in ratio T i – time constant of integration;
with the main output. T d – time constant of deviation;
8. The front panel of microprocessor module FG o – range of FG;
is shown on Fig. 1 and it consists of: b o – initial value of the actuator (%).
8.1. 4-decade red display “F” for indication The controller is with analog current output
in % of the factor of grinding FG; 0(4)~20mA. The controller can work into nor-

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mal regime (nor) as ε = SP-FG or into inverse For the programming is developed menu by
regime (inv) as ε = FG-SP. mean of which are chosen the parameters of the
For improving of the controller operation control loop. The menu of programming is with
a extra programmable zones are anticipated: a shape of reversed tree, containing 2 levels of
dead zone (n), where the controller don’t diverge and 3rd level for programming (Fig. 2).
works and zone of linear operation (L), out By the choice of Cn-C from 1st level and ENT it
that the actuator in dependence on sign of is reached 2nd level of programming of the loop,
ε get maximum or minimum. Most of the that has 2 variants:
mills have different transitional characteris- 1) C-F – programming of the factor of
tics at loading and discharge and due to in grinding FG.
menu are anticipated two groups of adjust-
2) C-Pid – programming of the controller.
ments for P, T i , T d , n and L, which depend
on sign of ε .

- - Cn-rS

- - - rS-un

Fig. 2 Algorithm for programming of MILLCONT 1

2) FO—order of digital filter (2nd, 3rd or 4th);

Programming of the factor of grinding FG (C
– F) 3) CA—gain coefficient of the output am-
plifier (1, 2, 4 or 8);
By the choice of C – F from 2nd level and
4) CF—coefficient of FG (50~9999);
ENT it is reached 3rd level, where are pro-
grammed the parameters of FG: 5) tA—average interval of FG (1~60s);
1) Fr—cutting frequency of digital high fre- 6) LF—low value of FG (0~1999);
quency filter (1~1600Hz); 7) HF—high value of FG (0~1999);

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 8) AL—low value of alarm (in the range of you sure?). By ENT again and the recording is
FG); performed as by PAR/QUIT it is refused.
9) AH—high value of alarm (in the range of Floating densimeter
FG);
Floating microprocessor densimeter (DENSI-
10) iF—Type of FG on the display (F-FG or METER) is purposed for measuring of the den-
F-PrO-FG in % defined by LF and LH)； sity of the ready pulp. The special float with
11) rO—type of analog FG current output: volume about one liter and weight 2000 g is
0(4)~20mA； hung on precise weightmeasuring sensor and it
12) tO—type of analog FG output: normal or is immersed into the pulp. The measuring ele-
inverse (nor or inv). vating power by the float with negative floata-
bility is proportional to the density (Penzov,
Programming of the controller parameters
Marinov, 1998). The signal from the sensor is
(C-Pid)
sent to microprocessor module where by special
By the choice of C-Pid from 2nd level and software it is performed calibration, calculation
ENT it is reached 3rd level, where for debalance of the density, visualization and take out of the
ε >0 are programmed the followed controller information.
parameters: The density of the pulp is calculated by the
1) PP—gain coefficient P (0~9999); formula:
2) IP—time constant of integration T i (0~ D = (−Ff + CA) Cn
9999s); where:
3) dP —time constant of deviation T d (0~
.

D—density of the pulp, g/L;

9999s); Ff—the weight measured from weightmea-
4) nP—dead zone (0~100% from the range suring sensor is equal to the difference between
of FG); deadweight of the float and elevating power;
5) LP—zone of linear operation (1%~100% CA—coefficient which is equal to the dead-
from the range of FG). weight of the float + eventual settling;
For debalance ε<0 are programmed corres- Cn—coefficient for normalizing of the den-
ponding: Pn, In, dn, nn, Ln in the same limits.
sity if the volume of the float is different from a
1) bo—initial value of the controller output liter.
(0 ~100%); DENSIMETER measure the density of the
2) do—restriction of the increasing of the pulp in the range 1000g/L up to 1800 g/L. The
control action between two consequence tacts range can program with a view to increase the
(0,1%~100%); accuracy. The sensor signal can send to the dis-
3) PL—tact of the control law (1~650s); tance up to 200 m without additional amplifier.
4) tL—control output(nor−normal or inv - The adjusted error of measuring is under 0.5%.
inverse); The front panel of microprocessor module
5) O1—current output No 1 of the controller shown in Fig. 3 consists of:
(0 ~20mA or 4~20 mA); 1) 6-decade display for indication of the den-
6) O2—current output No 2 of the controller sity, for calibration and for a programming.
(0 ~20mA or 4~20 mA); 2) Line of 4 light diods for indication of situ-
ations at operation of the module.
7) O3—current output No 3 of the controller
3) Line of 4 buttons for service of the module
(0 ~20mA or 4~20 mA); into mode of operations.
8) OH—limitation in % from above of the
controller current output (−5%~105%);
9) OL—limitation in % from below of the
controller current output (−5% ~105%).
After programming it is reached 1st level of
Cn-Stor. By ENT it is recorded on FLASH
memory as it is obtained a message SurE (are

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 developed menu (Fig. 5) with a shape of re-
versed tree, containing up to 3 levels for a

diverge and one level for a programming.

1—
Fig. 3 Front panel of the microprocessor module 2—
3—
Terminal device for outer connection of the 4—
5—
module consists 16 terminals.
The microprocessor module is inserted into
PVC box with dimensions 55mm×85mm×
105mm into which are installed plates: of the Fig. 4 Inserting of DENSIMETER in the technological
flow
module, of the front panel and of the terminal
device.
In order to escape the influence of the tech-
nological flow on the measuring the float of
DENSIMETER is installed into calm media
(Fig. 4)
For the programming of DENSIMETER is

Fig. 5 Algorithm for adjustment of DENSIMETER

By the choice of Co-Pd from 2nd level and ENT it is reached 3rd level where are pro-

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grammed the parameters for adjustment of the tic. By ENT it is reached the 3rd level CA-Lo.
densimeter: On the sensor is hung weight 1000 g , by ENT
1) CA−−Coefficient equal of the deadweight the calibration of this point is confirmed and on
of the float + eventual settling (Range 0~3000). the display CA-H1 is appeared. On the sensor
2) Cn−−coefficient for normalizing of the weight 500 g is hung and by ENT the calibra-
density if the volume of the float is different tion of this point is confirmed. The recording
from a liter. from RAM on FLASH memory is performed
3) tA−−average interval of the density
(1~60s). from CL-Stor of 2nd level and ENT is pushed. It
4) Ld−−low value of the density (0~1999). obtains a message SurE (Are you sure?) and by
ENT the recording is performed.
5) Hd−−high value of the density (0~1999).
At the measuring of the density of the pulp
6) AL−−low value of alarm (in the range of
on the float are lay up settlings which change
the density).
the reading of DENSIMETER. Then the float
7) AH−−high value of alarm (in the range of
must clean up or the coefficients CA and Cn to
the density).
be reprogram.
8) rO−− range of analog output (4~20mA or
0~20mA). MICROPROCESSOR CONTROL
After programming of 4th level it is reached SYSTEM OF THE ORE GRINDING
nd
2 level of Co-Stor. By ENT it is recorded on PROCESS
FLASH memory as it is obtained a message
The developed automatic system for ore
SurE (are you sure?). By ENT again and the
recording is performed as by SEL it is refused. grinding control in single—stage ball mill have
The calibration of the input signal from the schematic diagram which is given in
weightmeasuring sensor is performed as from Fig. 6. The purpose of the system is:
1st level it is reached CAL and by ENT,▼,▲ -
the 2nd level CA-tArA. The calibration is per-
formed for two points of the sensor characteris-

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 Fig. 6 Schematic diagram of the grinding system

 to measure the loading (filling level) of

Measuring loops of technological parameters
the mill with ore.
 to stabilize automatic the set loading by F—The weight flow rate of the ore sent to
change of the flow rate of the inlet ore. the mill.
 to keep up the set ratio ore-water at the V—The revolution of the belt feeder.
control process of the mill loading. L—The loading (the filling level) of the mill.
 to measure and stabilize the density of
D—the pulp density of the ready product.
the ready pulp by correction of the water
sent into the classifier. Loops for stabilization of technological pa-
The aim is to be increased productivity of the rameters
grinding aggregate as well to be improved the  The weight flow rate of the ore sent to the
quality characteristics of the ready pulp to be mill by the signal F with an effect on the
improved at minimal interference of the exploi- transistor frequency inverter 8, changing
tation personnel (Penzov et al., 2006). the revs of the band feeder 2. The control-
The system realizes the following loops for ler of this loop is configured from the
measuring and stabilization: control system.

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  The flow rate of the water sent to the mill  The durability of the lining and the grind-
in set ratio with the weight flow rate of the ing bodies is increased about 15% ;
ore.  The average square deviations of the
 The loading (the filling level) of the ball ground product by fineness of grinding
mill with ore. The loop includes the sensor and density is decreased with an average
L and the microprocessor module MILL- of 1.3 times in compare with the manual
CONT 1. The main output of the control- control of grinding process;
ler of MILLCONT 1 is connected in  The term of buyback of the system is un-
cascade with the loop for weight flow rate der 6 months.
of the ore. The subordinated output of the Besides these good economic results the sys-
controller is acted on the inlet water. tem improves the overall labour organization.

REFERENCES
 The density of the pulp for flotation. The
loop contains DENSIMETER, the con- Marinov, D, Penzov, T, 2006. New sensor and microprocessor
troller, configured from the control system modules for optimum loading of separator ball mills, ZKG
and the actuator 10 with the water tap. International, 6/2006.
Penzov, T, Marinov, D, 1998. New automated system for mill
CONCLUSION control, 9th IFAC Symposium on Automation in Mining

The new automatic system is already imple- Mineral and Metal Processing MMM’98, Duesseldorf,

mented on single-stage mill working in close Germany.

cycle with classifier. The nowadays experience Penzov, T, Marinov, D, 2005. A new microprocessor system for

in ore grinding process automation shows the grinding process control, First Balkan Mining Congress,

following: Varna, Bulgaria.

 The productivity of the mill is increased

Penzov, T, Vragov, I, Lalov, I, 2006. New microprocessor sys-

from 10% up to 30%. tem for control of ore grinding process, XXIII International

 The specific power consumption is de-

Mineral Processing Congress, Volume 1, Istanbul.

creased approximately with the same per-

cents;

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