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FLSmidth Launches SAGwise™ Total Process Control, a Sensory and Process Optimization System

Published: March 26, 2018 |

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FLSmidth launches a sensory and process optimization system designed to optimize the use of the three main consumables in SAG milling: power, media, and liners.

The SAGwise™ total process control system reduces energy consumption by up to 6 percent. This is a significant reduction considering that, by far, mills are typically the single largest consumer of power within a processing plant. Other benefits include up to 45 percent reduction of ball-on-liner impacts, prolonging liner life and minimizing media degradation.

Through specially-designed acoustic sensors and proprietary process control software, induced impacts, generated inside the SAG mill, are monitored and interpreted by the SAGwise™.It registers undesirable high-energy impacts caused by steel balls striking the mill liners categorised as critical impacts. Then, an advanced process control solution makes small and frequent adjustments to mill operational conditions that reduce the critical impacts, improving ore reduction and energy efficiency.

“This solution employs state of the art process control technologies to reduce critical impacts to the desired targets, stabilizing and then optimizing the operation of the SAG mill. Multiple process control technologies, such as model predictive control and fuzzy logic, are embedded into the solution, modelling both the process and the human operators,” said Global Product Line Manager for Automation Process Optimization, King Becerra.

Weighing up to 4 tons each, replacing worn mill liners requires significant effort. This is associated with downtime to complete the replacement affecting plant productivity.

“High mill availability is crucial. A gold processing plant I visited recently valued their SAG mill downtime at US$ 130,000 per hour. Under normal conditions, the return on investment of SAGwise™ total process control is 6 months, but if we factor in reduced unscheduled maintenance, the return is a lot sooner,” said Global Product Manager for Liners, Jack Meegan.

Extending the life of mill liners pays off in many areas beyond prolonging the initial replacement, cost of what can be over 1 million US dollars. FLSmidth’s customers also benefit from improved safety performance, stemming from reducing the number of times that employees are required to move the heavy equipment inside the mill, improved inventory management, and better predictive maintenance planning.

SAGwise™ total process control is an innovative solution of how FLSmidth uses technology, process knowledge and practical experience to further enhance productivity of SAG mills.


About FLSmidth
FLSmidth is the market-leading supplier of productivity to the global mining and cement industries. Headquartered in Copenhagen, Denmark, and with offices in more than 50 countries, FLSmidth delivers engineering, equipment and service solutions to customers worldwide. Productivity, sustainability, and quality are focus areas for the 12,000 employees in FLSmidth. The company generated revenue of DKK 18 billion in 2016.

To stop by FLSmidth’s website, CLICK HERE


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