The SAG Mill ACE is an APC solution that manages the SAG mill and reclaim feed rate. Its main goal is to maintain stable mill filling for consistent grinding performance and maximum production while reducing energy consumption.

It adjusts feeder speeds based on operator input, stockpile levels, and ore characteristics, minimizing disturbances and preventing premature liner wear through acoustic monitoring. The system also ensures that key operating limits are maintained.

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Ball Mill ACE is an advanced control solution for the Ball Mill and related equipment. It maintains cyclone feed pressure and density while managing the sump level, which is crucial for stable P80 and improved flotation recovery.

Key features include:

• Control of hydro-cyclone pressure and solid percentage
• Reduction of P80 variability
• Sump level management and upstream disturbance control
• Overload protection for the sump pump.

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Flotation ACE is an advanced process control solution that maintains stable froth levels in flotation cells, enhancing efficiency and recovery rates.

Key benefits include:

• Stabilized cell operation levels.
• Automatic froth speed monitoring and adjustments.
• Increased recovery rates.
• Real-time valve health evaluation with corrective actions.
• Controlled addition of reagents.

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The Thickener ACE is an APC for thickener management.

• Density Control: Automatically adjusts the bed pressure set point to reach target density.
• Bed Pressure Control: Regulates bed pressure by changing the speed of the underflow pumps, with constraints for bed level and torque.
• Interface Level Control: Manages the interface level adjusting flocculant dosage

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The Plant-Wide Supervisor ACE solution represents the next generation of the successful ScreenHouse ACE. Over the past four years, the ScreenHouse ACE solution has transformed operational performance across multiple sites in Australia. This solution has also served as a model for primary, secondary, and tertiary crusher solutions in South America, demonstrating its versatility and effectiveness in various mining operations.

Built on this proven foundation, the Plant-Wide Supervisor ACE is the largest and most comprehensive version ever designed by the ANDRITZ Mining Team, demonstrating versatility and effectiveness for mining operations. It also encompasses additional plant areas such as the Coarse Ore Stockpile, Scrubber, WHIMS, and Thickener.

To achieve our vision for efficiency and sustainability, this solution includes a BEST-IN-CLASS energy-saving module designed to monitor and prompt energy consumption reduction per area for optimal plant performance overall. The energy-saving module features smart decisions to turn ON/OFF equipment automatically or increase/decrease speed.

With around 1000 pages in Metris Application Studio, the Plant-Wide Supervisor ACE is one of the most extensive control solutions developed in Metris, showcasing its vast scope and ambition. This project is currently in the commissioning phase at Fortescue’s Christmas Creek site and is set to revolutionize operations with its cutting-edge solution for process control and energy management.