Outotec MillSense

An intelligent mill analyzer

Outotec MillSense is an innovative, non-contact
analyzer

for

grinding

mills

providing

real-time

information about the mill charge and the grinding

process such as total charge volume.
The charge position and volume provided by
MillSense are fundamental factors that affect the state
of the grinding process and provide crucial insight on
the conditions inside the mill. Along with mill rotation
speed, charge characteristics such as toe angle can be
used to maximize the breakage energy and therefore
optimize the grinding efficiency. Charge volume is also
an essential measurement to avoid overloading and
underloading, which can cause cuts in ore feed and
severe damage to the lining and mill shell. Therefore, a
real-time mill charge analyzer is an indispensable part
of a modern advanced grinding control.

002 More out of ore!

Grinding control

draw and a rising mill weight indication. Unfortunately

Conventional control scheme

factors such as ore properties, mill speed, ball charge

Grinding control has conventionally been based on the

and liner wear, causing the maximum power draw level

power draw of the mill, with a typical goal of maximizing

to vary.

power draw is very sensitive to constantly changing

the power draw in the belief that the more energy is

Also, when an overload can reliably be detected

consumed the more energy is used in breaking the ore.

from the falling power, the mill is already slightly

This maximum power occurs at a point where overload

overloaded and major control actions must be taken to

is imminent and is typically detected by a falling power

bring the mill back to safe operating range. In addition,

the conditions inside the mill have a great effect on
how efficiently the total power draw is used in actual

Overload zone in power

breakage, and therefore, maximizing the power draw

may actually not achieve the ultimate goal of maximizing
breakage.
Using charge volume in control
The most important factors affecting the breakage

Process changes, e.g.

feed SG, mill speed,
ball charge, etc.

efficiency are in fact charge volume and mill speed.

Though the effectiveness of the grinding is affected

Power (kW)

by many other factors that are difficult to measure,

they are all linked to the charge behavior. The charge
volume not the mass is largely responsible for
mill overloads and the breakage energy. For instance,
A single power level can
represent a wide rage of
charge volume when process
parameters vary

a low charge volume results in high-energy impacts

as the grinding media falls a greater height from the
shoulder down to the toe. However, depending on
the charge level, mill speed and current liner profile,
some of these high-energy impacts may land beyond

Overload zone in volume

Charge volume (%)

the toe, which in excess will cause liner damage. On

More out of ore! 003

Sh

the other had, an attempt to protect the liners with a

ou

ld
.9 er

53

too high charge volume results in inefficient impacts,

which lowers the grinding efficiency and eventually
causes mill overloads. Therefore, a reliable on-line
volumetric charge measurement is vital in the control
and optimization of a grinding mill.
Since mill weight indicators such as load cells and
bearing pressure are affected by variables such as ore
density, ball charge and liner wear, they cannot provide
an absolute charge volume measurement and are
therefore not as suitable as volume or charge position
21
0

increasing interest in absolute volume measurement

200

measurements. This is why there has recently been an

22

Advanced grinding control solution

22 23
6 0
To .5
e

33.4 %

and estimation techniques.

24

0
250

MillSense is a basis for an advanced control

50
40
30
20
10

260

solution and is well accompanied by other advanced

instrumentation such as Outotec PSI on-line particle
size analyzers, ore feed size analyzers and automatic

is reduced, the desired particle size distribution is

ball addition systems. Outotec has extensive experience

maintained and the throughput of the mill is optimized.

in providing expert control solutions (Outotec ACT) for

This ensures cost-effective, trouble-free and efficient

grinding circuits. When Outotecs advanced control

operation of grinding circuits as well as a steady feed to

solution is applied, the variation of process parameters

downstream processes.

Liner
damage
Speed (% of critical)

Liner
damage

Reduced
impact area

Optimum

Reduced
impact area

Inefficient
impacts

Charge volume (%)

004 More out of ore!

Outotec MillSense Analyzer

Measurement principle
Outotec MillSense is based on the patented use of a

Non-contact charge measurement

ripple present in mill motors current draw caused by

Most of currently available mill charge measurement

lifters as they impact the charge. Changes in the charge

systems are intrusive, that is, they require instruments

position are seen as detectable variations in the ripple.

to be placed in a hostile environment inside the mill or

Recent developments in the analysis of the ripple have

on the outside shell. This has several disadvantages

enabled the use of this phenomenon in many different

such as instrument wear and continuous replacement

mill configurations.

needs, difficulties in power supply of the sensor and

The method uses advanced mathematical tools

a need for wireless signal transfer. This amounts to

and specific knowledge of the mill and the lining to

complex instrumentation and extensive maintenance

determine the charge position accurately and robustly.

needs. Attempts have also been made to employ models

Noise and other disturbing variance in the current

and more easily available measurements, but they can

caused, for instance, by mechanical asymmetries are

be difficult to commission and maintain accurate.

effectively filtered out by the data analysis.

MillSense

is a non-contact analyzer, which

MillSense

also

has

an

automatic

speed

makes use of high-frequency sampling of the mill

compensation algorithm, which allows its use in

motors current draw with special fast response

modern speed-controlled mills.

current sensors. An inductive proximity switch is used

for synchronization and accurate speed measurement.

Outotec MillSense Analyzer system

With this simple instrumentation Outotec can provide a

MillSense consists of a main MillSense Analyzer

robust charge analyzer with little need for maintenance.

Cabinet (MAC) and multiple Signal Junction Cabinets

In addition MillSense does not impose any major

(SJC, one for each drive).

restrictions on the lining type or material.

More out of ore! 005

The junction cabinets are located near the current

measurement points for the main power lines of
the mill motors while the main cabinet can be freely
placed. The cabinets are connected with a dedicated
fiber optic Ethernet-network. Inside the main analyzer
unit, the signals are collected and analyzed in an
industrial high-performance computer. The analyzer
provides operators with user interface via a standard
Web browser with monitoring functionalities. In the
case of more advanced requirements or configuration,
a remote desktop connection can be used to manage
the analyzer.
A single analyzer is capable of analyzing the charge
of up to four mills. Analysis results and calculated
measurements can be transferred to third party
systems via the provided OPC Server or the integrated
SQL database.

Cyclone battery

Ball feeder

BC

Water
M

Particle size

Ball addition

DC

Feed size

FIC

FS

Ball addition

Density control

JIC

PSI

WIC

Fresh feed

PT

Water

SAG mill
M

Bearing pressure /
Load cells

PT

Power / Torque

JT

TT

Speed control

SIC

MillSense charge analyzer

MS

FT

DIC

FIC

Acoustic

Ball mill

Density control
WT
LIC

Pump sump

Level control

006 More out of ore!

Automation

Outotec
Remote support

Control room

Plant network

MillSense Analyzer
Cabinet

Mill 1 (single drive)

Mill 2 (dual motor drive)

Signal Junction
Cabinet

EtherCAT
network

EtherCAT
network

115/230
VAC

Local access

Current sensors

115/230
VAC

EtherCAT
network

115/230
VAC

Current sensors

Signal Junction
Cabinet

115/230
VAC

115/230
VAC

Current sensors

Current sensors

Rotation
sensor

Rotation
sensor

Rotation
sensor

MillSense General System Layout

Variable speed drive with a frequency converter

Switchgear
Circuit breaker

Electrical Room

Transformer
bunker

Frequency
converter
cabinet

Electrical Room

MV

Fixed speed

MV
Circuit
breaker

Switchgear

MillSense
Current Sensors

Step down
Transformer

f1

f2

Frequency
converter

MillSense
Current Sensors

Mill motor
0 - 100% speed

Typical location of MillSense Current Sensors with different mill drives

Mill

Mill

M
3~

M
3~

Mill motor
Fixed speed
Liquid resistance
starter (LRS)

Plant floor

Ethernet (copper)
EtherCAT (fiber optic)
Current signal cable
Digital signal cable

Signal Junction
Cabinet

Electrical room

EtherCAT
network

Signal Junction
Cabinet

Mill 3 (single drive)

More out of ore! 007

Specifications for Outotec MillSense

Performance
Suitability: For primary AG and SAG mills
Number of measured mills: 1 to 4

Remote diagnostics connection:

Ethernet or dial up modem line
Remote display and configuration: Web server, remote
desktop connection

Measurement update interval: Once in a revolution

System components
Current sensors (one for each current
phase and drive of each mill)

Installation requirements
Operating ambient temperature at sea
level: +5 - +45 C (41-113 F)
Environmental classification: IP56

Inductive proximity switch (one for each mill)

(Designed to meet NEMA 4X)

Signal Junction Cabinet SJC (one

Power supply: 115 / 230 VAC 10% 60 / 50 Hz (MAC and

for each drive of each mill)

SJC)

MillSense Analyzer Cabinet MAC

Dimensions:

(one for up to four mills)

Operator interface PC (optional)

Remote monitoring PC (optional)

Web server user interface

Main status and event log

MAC: 600 x 378 x 221 mm (H x W x D)

23.6 x 14.9 x 8.7 (H x W x D)
SJC:

600 x 278 x 221 mm (H x W x D)

23.6 x 10.9 x 8.7 (H x W x D)

Weight:

MAC 27 kg (60 lbs)

SJC 20 kg (44 lbs)

Mill-specific status with graphical

representation of charge
Trending, measurement monitoring
Event log

Outotec quality assurance

Outotec MillSense is CE marked

Retrieval of measurement data from

according to the European

the integrated database

Union Directives. Outotec

is ISO 9001 accredited

Measurement outputs
Charge toe and shoulder angle
Ripple amplitude
Full scripting environment (VBScript)
available for customized calculations
User configurable model based estimators (Extended
Kalman Filter)

Data connections
Control system connection:

Ethernet OPC Server

Via integrated SQL database

COM component interface (ActiveX)

Customized connections upon request

and has a quality management policy to ensure

that the expectations of customers are met.

automation@outotec.com
www.outotec.com
Copyright 2009 Outotec Oyj. All rights reserved.