The PCM™ was developed to provide an online view of the dynamics of the mineral processing plant. By monitoring the chemistry in real time, the process can be optimised and metallurgical performance improved.
“The ore body is quite variable and the chemistry may change within the hour. In the past we haven’t been able to see these new chemistry variables that Magotteaux have developed online and then make an association with what is changing with the minerals,” said Karageorgos.
“If the mineral recovery or grade drops you need to understand the dynamics of the chemistry. In the past you had to take a sample, send it to a lab for testing and wait days or weeks for answers but with PCM we can see what is happening within minutes,” he said.
The PCM has been tried and tested in mineral processing plants for the past few years. Manta invested the time in engineering the solution to be robust enough to cope with the harsh environments of the processing plants. It can cope with being exposed to slurries and salts as well as the weather elements.
Complete control technology
Manta Controls specialises in implementing the best possible control strategy for a particular piece of equipment or area of the plant. To achieve this for PCM, Manta developed a unique Manta Cube system that utilises advanced control fundamentals.
The ability of PCM to provide real time information that helps optimise mineral quality and recovery is the result of the complete integration of communication and high-level control functions. To achieve this, Manta Controls leveraged the inherent flexibility and scalability of the Rockwell Automation Integrated Architecture platform.
“We decided to choose the Rockwell Automation control system because it’s one of the most widely used systems in the world. This makes installation of PCM easy in any system whether it is a Rockwell Automation site or not, communication is easy either way. Additionally, they provide a lot of knowledge and support about how to optimise the system and the latest new developments,” said Karageorgos.
Like the Magotteaux Mill, PCM is also controlled by CompactLogix, which has all the functionality of ControlLogix® and is also compatible with the advanced control signals generated by the Manta Cube. FactoryTalk View and Historian provide robust and reliable functionality in a single software package. The Historian is used to track and log process data on the machine and is easily integrated with CompactLogix.
According to Jonathan Footman, solutions architect at Rockwell Automation, “Integrated Architecture was the most appropriate choice for this application because it is a scalable solution that offers the convergence of control and information systems, delivering both real-time and historical data and reduced engineering time.”
Australian innovation, global application
Leveraging new technologies to develop innovative products that can help mining companies improve productivity and profitability remains key to meeting future challenges. Both the Magotteaux Mill and PCM provide a means that can help improve productivity through improved mineral recovery and quality both in Australian mines and around the world.
Both machines are manufactured in Adelaide, South Australia to Australian machine standards. They are exported globally and comply with relevant safety standards. By incorporating technologies with inherent flexibility and scalability, the machines can be integrating into a range of mineral processing facilities.
“We enjoy a mutually beneficial and productive relationship with Magotteaux. At Manta, we ensure that the machines deliver all the parameters required for effective process control and Magotteaux makes sure that the units work well in terms of improving mineral recovery,” said Karageorgos.