Tag Archives: Process IQ

Orway and Process IQ form JV focused on remote mineral processing consulting

Orway Mineral Consultants (OMC) and Process IQ say they have formed an incorporated joint venture, Orway IQ Pty Ltd, to deliver a remote optimisation consulting service for the mineral processing industry.

MillROC (Milling Remote Optimisation Consulting) will initially focus on comminution circuits, the partners said.

Headquartered in Western Australia, Orway IQ is led by Pieter Strobos (Chairman of the Board), Fred Kock (CEO), Brian Putland and Daniel Van Der Spuy (Executive Directors).

Process IQ, meanwhile, was among eight companies nationally to share in A$15.6 million ($10.6 million) of funding to support collaboration and innovation, and address mining equipment, technology and services (METS) sector priorities, as announced earlier this year.

Its project, which included Orway as one of three partners, was aimed at enabling grinding experts to interact directly and in real time with grinding circuits on remote mine sites to ensure they are operating at their most productive levels. “The project will develop automated artificial intelligence software to emulate the experts as there is very limited supply of this specialist expertise, leading to increased processing efficiency globally,” METS Ignited said.

The joint venture draws on Orway’s expertise in comminution design, modelling and optimisation and Process IQ’s expertise in the Industrial Internet of Things (IIoT), cloud-based computing, process control, automation and instrumentation, the companies said. Together the companies claim to have served the mining industry for more than 50 years.

Orway IQ’s MillROC uses real-time data in online process models and communicates the findings to the client, according to the companies. The product is a cloud-based reporting of all plant data related to circuit performance and optimisation, available anytime, anywhere – via the internet. Orway IQ expert consultants review circuits from around the world daily from its operations centre in Perth.

Orway’s Strobos said: “The joint venture company is aligned with the METS Ignited initiative to assist with the growth and innovation of the business. Process IQ, OMC and now Orway IQ are at the forefront of the digital transformation in the mining industry, having been recognised for their ground-breaking work in this space.”

Strobos continued: “We are receiving tremendous support from both Federal and State government and our consulting service, MillROC, has been recognised as having huge implications as a new product category for the mining industry.”

Orway IQ has also been chosen to participate in the RISE Accelerator program supported by the Western Australia Government Department of Jobs, Tourism, Science and Innovation, The Queensland Government, NERA and METS Ignited – which is run by KPMG. The program has been developed to spearhead innovation into industry and equip METS companies with the skills, capabilities and support to develop their innovation and grow their businesses.

Robotics and automation projects among latest METS Ignited funding recipients

Australia’s Minister for Industry, Science and Technology, Karen Andrews, has announced seven mining supply businesses as the recipients of A$4.1 million ($2.9 million) in innovation funding under the METS Ignited Collaborative Project Funds.

The recipients of the funding will now be able to launch eight collaborative industry projects delivering highly-advanced solutions to a variety of mining challenges and contribute to the growth and capability of the METS sector, according to METS Ignited.

This funding is part of a four-year, A$15.6 million commitment made by the Australian Government to incentivise collaboration and address METS sector priorities. The funding established the METS Ignited Collaborative Project Funds, which support industry-led projects to improve the productivity, competitiveness and innovative capacity in the METS sector.

Today’s announcement at Mineral Technologies, on the Gold Coast of Australia, is the third tranche of funding. METS Ignited received 26 grant applications and has awarded the funds to businesses specialising largely in robotics and automation, data analytics, data platforms, Internet of Things and business and professional services. The recipients are: Mineral Technologies, Premron, Austmine, Roobuck, Process IQ, AMOG (x2) and Magotteaux.

Acting CEO of METS Ignited, Ian Dover, said: “Active collaboration across the ecosystem is core to accelerating commercialisation of innovation and has been lacking in the METS and mining sector, where historically relationships have been in the main transactional.”

“Facilitating such innovation is part of the mandate for METS Ignited. It’s vital we support the application of influential future technologies across the METS sector and maintain Australia’s competitiveness.”

Recipients of the Collaborative Project Funds are required to secure equal or greater investment from an industry partner. As a result, the total value of the eight projects is A$11 million.

The largest fund recipients were Queensland-based Mineral Technologies and Premron, awarded A$1 million each. Mineral Technologies’ automation of the Roy Hill Iron Ore beneficiation plant project automates the gravity separation spiral process used in the mine to optimise the concentration of lower-grade ore into higher value ore for export, METS Ignited said.

Roy Hill CEO, Barry Fitzgerald, said: “I am delighted the government is supporting our partnership with Mineral Technologies – a project that seeks to enhance the operational efficiency of our mine, delivering more high-grade product while reducing waste for the same operational cost.”

The automation of spiral control in the Roy Hill beneficiation plant will materially improve the concentration of ore into high value product for export, according to Roy Hill. More high-grade product and less waste will be produced for the same feed and processing cost, delivering value to both the environment and Roy Hill’s bottom line, the company said. Once proven effective at Roy Hill, the technology can be commercialised and rolled out at similar operations across the world.

“This innovation project will deliver a step-change improvement through real time control of our 720 spirals, enabling our processing plant to dynamically respond to the natural variability of the material it is treating,” Fitzgerald said.

Premron’s Continuous Haulage System (CHS) project, meanwhile, will revolutionise coal mining in underground mines, according to METS Ignited. It eliminates the use of shuttle cars, used to take the coal cut from the wall of the mine to a transfer point further away in the mine (dead time). CHS will see the coal go straight to a conveyor belt and out of the mine.

Other projects that received funding in this round include: sensor technology to monitor the location of people and equipment underground; artificial intelligence technology to emulate the role of a grinding expert; automated sensor detection for oversized rocks; a predictive analytics tool that pinpoints the best time for equipment descaling; a METS career pathway programme; and a device to give more detailed information on the chemistry inside the grinding mill while it is operating.

METS Ignited said: “Collectively, the projects will benefit the mining sector by optimising the value chain, increasing productivity for mining and mineral processing, supporting and enhancing environmental management, and improving operational safety.”

The project fund recipients include:

Automation of the Roy Hill Iron Ore beneficiation plant

  • Recipient: Mineral Technologies
  • Partners: Roy Hill
  • Collaborative project funds: A$1 million
  • Industry investment: A$1 million
  • This project automates the gravity separation spiral process used in the mine to optimise the concentration of lower-grade ore into higher value ore for export.

CHS

  • Recipient: Premron
  • Partners: Gauley Robertson Australia, Kestrel coal mine
  • Collaborative project funds: A$1 million
  • Industry investment: A$1.13 million
  • Continuous haulage will revolutionise coal mining in underground mines. It eliminates the use of shuttle cars, which are used to take the coal cut from the wall of the mine to a transfer point further away in the mine. CHS will see the coal go straight onto a conveyor belt and out of the mine.

Austmine METS career Pathway Program

  • Recipient: Austmine
  • Collaborative Project Funds: A$240,000
  • Industry investment: A$1.76 million
  • This project places university students as interns in METS companies around Australia, increasing the interest level and uptake of graduates into the METS sector

The OVERwatch Platform

  • Recipient: Roobuck
  • Partners: Redpine Signals, Northparkes Mines, University of Wollongong
  • Collaborative project funds: A$600,000
  • Industry investment: A$1.5 million
  • This project develops sensors and software to track the location of people and machinery working in underground mines and ensure that collisions are avoided. This is a complex project as there is limited communication options underground (eg no Wi-Fi).

Remote grinding optimisation and support centre

  • Recipient: ProcessIQ
  • Partners: Orway Mineral Consultants, Jamieson Consulting, Curtin University
  • Collaborative Project Funds: A$620,000
  • Industry investment: A$780,000
  • This project enables grinding experts to interact directly and in real time with grinding circuits on remote mine sites to ensure they are operating at their most productive levels. The project will develop automated artificial intelligence software to emulate the experts as there is very limited supply of this specialist expertise, leading to increased processing efficiency globally.

Automated Oversize Detection

  • Recipient: AMOG
  • Partners: Omniflex
  • Collaborative Project Funds: A$150,000
  • Industry investment: A$220,000
  • This project involves developing sensor equipment that alerts the mine when rocks are too big to process through the crushing and grinding equipment. Blockages in the crushing and grinding circuits are costly and time consuming. Haulage trucks with oversized rocks will be diverted to a separate location in the mine, which avoids stoppages.

Smooth Operator leach circuit process optimisation

  • Recipient: AMOG
  • Partners: Lithium Consultants
  • Collaborative Project Funds: A$220,000
  • Industry investment: A$220,000
  • This project involves developing a predictive analytics tool that allows copper and nickel mines to pinpoint when they should close equipment for descaling. Closing equipment too late or early is very costly. There is a very large global market for this product.

Commercialisation of pulp chemistry monitor for the mining industry

  • Recipient: Magotteaux
  • Partners: Hydrix, Manta Controls, Newcrest Mining
  • Collaborative Project Funds: A$250,000
  • Industry investment: A$310,000
  • This project involves developing a device to give more detailed information on the chemistry inside the grinding mill while it is operating. Grinding and flotation circuits use many chemical inputs in order to extract minerals from the ore. Getting the chemical balance right in the mill and the next stage of floatation is critical to removing as much of the valuable mineral as possible. The percentages of the yield vary between 85% and 95% and a 1% improvement in yield will deliver a very large financial benefit to the mine.