1) Advanced Analysis
Our analysis services provide detailed evaluations of both equipment and process performance, ensuring potential issues are addressed before they impact operations. Using advanced data analytics and machine learning, we deliver precise insights that allow for fine-tuning operations and optimizing output.
- Detailed Performance Evaluations: Assess equipment health and process efficiency to proactively address performance issues.
- Data-Driven Optimization: Apply advanced analytics to optimize production rates, energy consumption, and resource utilization.
- Predictive Maintenance: Identify potential equipment failures before they occur, minimizing downtime and extending the life of key components.
2) Smartification Services
Our smartification solutions integrate automation, IoT, and AI technologies into mineral processing operations, transforming traditional systems into intelligent, real-time decision-making platforms. This enhances process control, improves safety, and enables immediate, data-driven adjustments for increased efficiency.
- Automation & Control: Implement AI-driven process control systems for enhanced decision-making and process optimization.
- IoT Integration: Enable real-time monitoring of equipment and processes, improving responsiveness and overall system performance.
- Safety Improvements: Leverage smart technologies to enhance operational safety and reduce human error.
3) Liner Wear Prediction System for SAG Mills
One of our key innovations is the Liner Wear Prediction System for SAG Mills. This system accurately forecasts liner wear and generates a real-time 3D model of the worn liner. By simulating and monitoring the load profile within the mill, we provide valuable insights for optimizing performance, reducing downtime, and improving overall efficiency.
- Real-Time Monitoring: Track liner wear and adjust operational parameters to maximize mill performance.
- 3D Visualization: Create detailed models of worn liners to forecast wear patterns and schedule maintenance more effectively.
- Process Optimization: Use load profile simulations to fine-tune mill operation and improve processing efficiency.
4) Advanced Online Condition Monitoring for Hydrocyclones
Our online condition monitoring system for hydrocyclones uses three specialized sensors to provide real-time data for optimized performance:
- Overflow Particle Size Prediction Sensor: This sensor uses ultrasonic waves (100 kHz to 200 MHz) to measure particle sizes in the hydrocyclone’s overflow, ranging from 50 to 300 micrometers. AI algorithms analyze the data and categorize overflow conditions as fine, normal, coarse, or very coarse, alerting operators in real-time to critical conditions, preventing inefficiencies, and avoiding equipment damage.
- Underflow Choking Detection Sensor: Utilizing piezoelectric technology, this sensor detects blockages in the hydrocyclone’s underflow, triggering an immediate alarm in the control room to enable timely intervention and prevent process disruptions.
- Underflow Shape Monitoring Sensor: This sensor uses a float to measure the real-time angle of the underflow exit, identifying the shape (spray, umbrella, or rope) to detect potential blockages and maintain optimal hydrocyclone performance.
Whether you’re looking to simulate a new process, optimize an existing one, or implement advanced smart technologies, PSDF’s services provide the tools and expertise you need for higher productivity, enhanced safety, and more sustainable operations.
