Stabilizing energy consumption of the SAG mill.

Maintaining consistent energy consumption is essential for anticipating energy needs reliably. This predictability plays a vital role in energy resource planning amid our current emphasis on energy efficiency and conservation. Accurately forecasting energy demand offers a strategic edge by enabling more effective energy allocation strategies, ensuring availability where it matters most. Predictability also mitigates the risks associated with energy shortages or surpluses, both of which can hamper operational efficiency and cost-effectiveness.

Moreover, a stable energy consumption pattern can enhance the efficient utilization of energy resources. Energy efficiency is pivotal in curbing the environmental impact of operations. By optimizing energy use, we can minimize wastage, boost productivity, and contribute to sustainability endeavors. Cutting down on energy waste reduces the need for excess energy production, thus alleviating the strain on our resources and lessening the environmental footprint of energy generation.

Furthermore, consistent energy consumption fosters operational stability, particularly in the context of a SAG mill, yielding more uniform production outcomes. Consistency in production is crucial for upholding operational efficiency and product quality. Fluctuations in energy usage can disrupt mill performance, affecting output quality. By stabilizing energy consumption, we ensure the mill operates consistently, ensuring uniform production results.

The stabilization of energy consumption also impacts SAG mill maintenance and longevity. Consistent energy use lessens strain on the mill's components, potentially reducing breakdowns and increasing maintenance intervals. This translates to long-term cost savings, reduced downtime, and heightened productivity.

A notable achievement of this solution is the marked decrease in power consumption variance. The solution halved the standard deviation of power from 246 kW to 128 kW. This reduction in variance underscores the solution's efficacy in stabilizing energy consumption, showcasing its ability to create a predictable energy demand and enhance SAG mill operational efficiency significantly.

Reducing variance in power consumption also bolsters the SAG mill's overall reliability and performance. Smoother, more consistent mill operation, with less power consumption fluctuation, minimizes unexpected issues or interruptions, enhancing productivity, output quality, and potentially extending the mill's lifespan.

In summary, stabilizing energy consumption in the SAG mill, facilitated by the solution's implementation, yields numerous benefits. These encompass predictable energy demand, optimized energy resource utilization, reduced energy wastage, consistent operational performance, and potential cost savings in terms of mill maintenance and longevity. The substantial decrease in power consumption variance highlights the solution's effectiveness and its potential to elevate sustainability and efficiency in SAG mill operations.

Key Results

  • Implementation of the solution reduced the variation (standard deviation) of the power by 2 times from 246 kW to 128 kW.

  • In some cases the water consumption was reduced due to stabilisation of the solid density in the SAG mill.

  • The implementation of the automatic control had a positive impact on the personnel. The amount of stress among the operators was reduced significantly which resulted in higher level of job satisfaction.

Challenges:

  • Balancing efficiency with environmental stewardship.
  • Integrating AI without disrupting current operations.
  • Ensuring AI's transparency and human oversight.
  • Achieving high AI reliability and uptime.
  • Adapting AI solutions to future sustainability goals.