Note: Descriptions are shown in the official language in which they were submitted.
TECHNIQUES FOR OPTIMIZING PERFORMANCE OF CYCLONES
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a technique for optimizing the performance of
cyclones,
e.g., operating in a hydrocyclone battery in a mineral extraction processing
system,
including extracting a mineral from ore.
2. Description of Related Art
By way of example, the aforementioned patent application serial no. 13/389,546
(712-2.330-1-1//CCS-0026, 43 and 44) discloses techniques for performance
monitoring
of individual cyclones using a SONAR-based slurry flow measurement, e.g.,
consistent
with that disclosed in relation to Figures 1A-1B, 2 and 3A-3D herein.
As disclosed in the aforementioned patent application serial no. 13/389,546,
in
many industrial processes the sorting, or classification, of product by size
is critical to
overall process performance. A minerals processing plant, or beneficiation
plant, is no
exception. In the case of a copper concentrator as shown in Figure 1A, the
input to the
plant is water and ore (of a particular type and size distribution) and the
outputs are
copper concentrate and tailings. The process consists of a grinding,
classification,
floatation, and thickening, as shown in Figure 1B. The grinding and
classification stage
produces a fine slurry of water and ore, to which chemicals are added prior to
being
sent to the flotation stage. Once in the flotation stage, air is used to float
the copper
mineral while the gangue (tailings) is depressed. The recovered copper is
cleaned and
dried. The tailings are thickened and sent to the tailings pond. The
classification stage
is critical to the performance of two areas of the process. These areas are
the grinding
throughput and flotation recovery, grade and throughput.
A grinding operation may include a screens and crusher stage and a mill stage,
that is typically configured mills in closed circuit with a hydrocyclone
battery. A
hydrocyclone is a mechanical device that will separate a slurry stream whereby
the
smaller particles will exit out the overflow line and the larger particles
will exit out the
underflow line. The overflow is sent to the flotation circuit and the
underflow is sent
back to the mill for further grinding. A collection of these devices is called
a battery. A
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hydrocyclone will be sized based on the particular process requirements. The
performance of the hydrocyclone is dependent on how well it is matched to the
process
conditions. Once the proper hydrocyclone has been chosen and installed, it
must be
operated within a specific range in order to maintain the proper split between
the
overflow and the underflow. The split is dependent on slurry feed density and
volumetric flow into the device. A typical control system will use a
combination of
volumetric flow, feed density and pressure across the hydrocyclone to control
the split.
Because of the harsh environmental and process conditions all of these
measurements
suffer from maintenance and performance issues. This can result in reduced
classification performance and reduced mill throughput. Flotation performance
is highly
dependent on the particle size distribution in the feed which comes from the
battery
overflow, thus it is dependent on the hydrocyclone classification performance.
The mill
throughput is highly dependent on the circulation load which comes from the
battery
underflow. Traditionally hydrocyclone performance has been determined by
evaluating
manually collected samples from the consolidated hydrocyclone battery overflow
stream. This technique is time consuming; the accuracy is subject to sampling
techniques; the sample is a summation of all the hydrocyclones from the
battery; and
has a typical 24 hour turnaround time. Therefore it is not possible to
implement a real
time control algorithm to monitor, control, and optimize the each individual
hydrocyclone.
Real time monitoring of each individual hydrocyclone would provide the ability
to
track the performance of individual hydrocyclones. This would enable the
following:
- The detection of hydrocyclones that require maintenance or have become
plugged.
- The detection of operational performance instabilities that cause extended
periods of roping or surging.
- The detection of chronic problems with certain hydrocyclones.
- Tighter classification control with changing throughput demands and feed
densities.
- Increased up time or availability of the hydrocyclone battery.
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Another common problem with hydrocyclone monitoring is reliably determining if
a feed gate valve is open or closed. This is typically done using two micro
switches.
One switch indicates the valve is in the open position and the other switch
indicates it is
in the closed position. These switches are typically unreliable and require
constant
maintenance. A reliable maintenance free method is needed.
Moreover, Figure 2 shows a classification stage generally indicated as 10 that
may form part of a mineral extraction processing system, like the one shown in
Figure
1A and 1B for extracting minerals from ore. The classification stage 10
includes a
hydrocyclone battery 12 that receives a feed from a grinding stage, as shown
in Figure
1B. The hydrocyclone battery 12 is configured to respond to signaling from a
signal
processor or processor control module 14, and provide an effluent, e.g., a
fine slurry or
slurry feed, to a flotation stage shown in Figure 1B. The classification stage
10 also
may include a hydrocyclone split 16 that receives the slurry from the
hydrocyclone
battery 12, and also may receive signaling from the signal processor or
processor
control module 14, and may provide some portion of the slurry back to the mill
stage
shown in Figure 1B, and may also provide another portion of the slurry as a
flotation
feed to a flotation stage shown in Figure 1B consistent with that described in
the
aforementioned PCT application serial no. PCT/US09/43438. The signal processor
or
processor control module 14 may also send to or receive from one or more
signals with
a control room computer 50 (see Figure 3A). The technique to track the flow
performance of individual cyclones operating in parallel on a single battery
is described
in relation to the hydrocyclone battery 12 (i.e. the single battery), the
signal processor or
processor control module 14 and the cooperation of these two components.
Figure 3A shows the hydrocyclone battery 12 (i.e. the single battery), the
signal
processor or processor control module 14 and the cooperation of these two
components
according to some embodiments of the present invention. For example, the
hydrocyclone battery 12 may include a first and second hydrocyclone pair 12a,
12b.
The first hydrocyclone pair 12a includes a first hydrocyclone 20 and a second
hydrocyclone 30. The first hydrocyclone 20 has a cylindrical section 22 with
an inlet
portion 22a for receiving via a feed pipe 9 the feed from the grinding stage
shown in
Figure 1B, an overflow pipe 24 for providing one portion of the fine slurry or
slurry feed
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to either the flotation stage shown in Figure 1B, or the hydrocyclone split 16
shown in
Figure 2, and has a conical base section 26 with underflow outlet 26a for
providing a
remaining portion of the fine slurry or slurry feed. See also Figure 3B, which
shows, by
way of example, the cyclone 20 in enlarged detail.
Similarly, the second hydrocyclone 30 has a cylindrical section 32 with an
inlet
portion 32a for receiving the feed from the grinding stage shown in Figure 1B,
an
overflow pipe 34 for providing one portion of the fine slurry or slurry feed
to either the
flotation stage shown in Figure 1B, or the hydrocyclone split 16 shown in
Figure 2, and
has a conical base section 36 with underflow outlet 36a for providing a
remaining
portion of the fine slurry or slurry feed.
As one skilled in the art would appreciate, the first and second hydrocyclones
20,
30 classify, separate and sort particles in the feed from the grinding stage
based at least
partly on a ratio of their centripetal force to fluid resistance. This ratio
is high for dense
and course particles, and low for light and fine particles. The inlet portion
22a, 32a
receives tangentially the feed from the grinding stage shown in Figure 1B, and
the angle
and the length of the conical base section 26, 36 play a role in determining
its
operational characteristics, as one skilled in the art would also appreciate.
At least one sensor 28 may be mounted on the overflow pipe 24 that is
configured to respond to sound propagating in the overflow pipe 24 of the
cyclone 20,
and to provide at least one signal containing information about sound
propagating
through the slurry flowing in the overflow pipe 24 of the cyclone 20.
Similarly, at least
one corresponding sensor 38 is mounted on the overflow pipe 34 that is
configured to
respond to sound propagating in the overflow pipe 34 of the cyclone 30, and to
provide
at least one corresponding signal containing information about sound
propagating
through the slurry flowing in the overflow pipe 34 of the cyclone 30. By way
of example,
the at least one sensors 28, 38 may take the form of a SONAR-based clamp-
around
flow meter, which is known in the art consistent with that described below.
The
SONAR-based clamp-around flow meters 28, 38 may be clamped in whole or in part
around some portion of the overflow pipes 24, 34. For example, the at least
one sensor
or meter 28, 38 may be mounted on the top of the overflow pipes 24, 34, or the
at least
one sensor or meter 28, 38 may be mounted on the bottom of the overflow pipe
24, 34.
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Alternatively, a pair of at least one sensor or meter 28, 38 may be mounted on
the
overflow pipes 24, 34, e.g., with one sensor or meter mounted on the top of
the overflow
pipes 24, 34, and with another sensor or meter mounted on the bottom of the
overflow
pipe 24, 34.
By way of example, in operation the SONAR-based clamp-around flow meters
28, 38 may be configured to respond to a strain imparted by the slurry, e.g.,
made up of
water and fine particles, flowing in the overflow pipes 24, 34 of the cyclones
20, 30, and
provide the signals along signal paths or lines 28a, 38a containing
information about
sound propagating through the slurry flowing in the overflow pipes 24, 34 of
the
cyclones 20, 30.
The classification stage 10 may include a signal processor or processor
control
module 14 (Figure 2), which is also shown in Figure 3A, having at least one
module
configured to respond to the signals along the signal paths or lines 28a, 38a
containing
information about sound propagating through the slurry flowing in the overflow
pipes 24,
.. 34 of cyclones 20, 30 operating in parallel on the cyclone battery 12 (see
also Figure 2),
and determine the performance of individual cyclones 20, 30 based at least
partly on
the information contained in the signals. The signal processor or processor
control
module 14 may also send to or receive from one or more signals along signal
path or
line 14a with the control room computer 50 (see Figure 2). The signal
processor or
processor control module 14 may also be configured to respond to signaling
containing
information about a battery flow rate, battery pressure, feed density, and
cyclone status
as indicated by individual gate valve positions of respective cyclones, which
are
provided from the cyclone battery 12 (Figure 2).
Furthermore, in order to implement the technology set forth in the
.. aforementioned patent application serial no. 13/389,546, embodiments
included at least
one sensor or meter 28a, 28b, 28c, 28d mounted on other parts of the cyclone
or
cyclone battery, or other parts or pipes connected to the cyclone or cyclone
battery,
including the feed pipe 9, or the inlet portion 22a, 32a, or the cylindrical
section 22, 32,
or the conical base section 26, 36, or the underflow outlet 26a, 36a, or some
combination thereof, as shown by way of example in Figure 3B.
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SUMMARY OF THE INVENTION
In its broadest sense, the present invention provides new and unique
techniques,
e.g., in the form of a method and/or an apparatus, to optimize the performance
of
individual cyclones operating in a battery of cyclones.
According to some embodiments of the present invention, the apparatus may
comprise at least one signal processor or signal processing module configured
at least
to:
respond to signaling containing information about particle sizes of solids
forming part of a slurry stream being fed with a common feed flow into a
battery
of cyclones; and
determine which combinations of cyclones in the battery produce overflow
that has undesirable particle size characteristics using a statistical
algorithm or
technique, based upon the signaling received.
The apparatus may also include one or more of the following features:
The at least one signal processor or signal processing module may be
configured
to provide corresponding signaling containing information about which
combinations of
cyclones in the battery produce overflow that has undesirable particle size
characteristics. By way of example, the corresponding signaling may include,
or take
the form of, control signaling to control the operation of the battery, e.g.,
including
information about certain combinations of cyclones to avoid, or preferentially
to use, to
minimize the total amount of coarse material having the undesirable particle
size
characteristics produced by the battery.
The signaling may include individual cyclone signaling sampled periodically
and
stored in a data set that can include information about other operational
parameters,
e.g., including which cyclones are open at a given time, a feed density, or a
feed flow
rate.
The at least one signal processor or signal processing module may be
configured
to analyze the data set over a predetermined period of time to extract
statistically valid
information as to which cyclones, and which combinations of cyclones, produce
overflow that has the undesirable particle size characteristics, e.g.,
including too large of
a particle size.
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The at least one signal processor or signal processing module may be
configured
to identify one or more individual cyclones that are underperforming,
including for some
physical reason attributable to any particular cyclone.
The at least one signal processor or signal processing module may be
configured
to analyze the data set to identify combinations of cyclones that produce
overflow
streams that have too coarse of a particle size, even though the individual
cyclones may
have no physical problems, including due to the fact that a physical pattern
of the
cyclones operating can affect the flow pattern in a distribution box that
feeds individual
cyclones.
The physical pattern of the cyclones may include either adjacent cyclones
operating next to each other in the battery, or alternating cyclones operating
in an
alternating pattern in the battery.
The at least one signal processor or signal processing module may be
configured
to determine if a type of pattern of the cyclones in the battery affects a
flow velocity in a
distribution box that can lead to non-uniform velocities within the
distribution box that
produces a density and particle size distribution that is not the same to each
cyclone in
the pattern.
The statistical algorithm or technique may be based upon one or more of the
following determinations:
determining an average total flow of coarse particles for each combination of
operating cyclones;
determining the combinations most frequently used in the battery, or
determining the combinations that produce the most total coarse material over
a
predetermined time interval.
The corresponding signaling may contain information as to which combinations
of cyclones in the battery to avoid, or preferentially use, to minimize the
total amount of
coarse material produced by the battery, including where the information may
be used
by an operator to make such a determination.
The at least one signal processor or signal processing module may be
configured
to identify one or more individual cyclones that are underperforming,
including for some
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physical reason attributable to any particular cyclone, based upon the
combinations
determined.
The signaling may be received from sensors mounted on overflow pipes of
individual cyclones that monitor a characteristic of the slurry stream, e.g.,
including a
percentage of solids at or above a certain particle size.
The percentage of solids at or above the certain particle size may include
P80, or
percent solids above 200 um, or a number of impacts of large particles above
12mm.
The apparatus may include the battery of cyclones.
The battery of cyclones may be configured so that between about 60% to 90% of
the cyclones are operated at one time, including where an operator can change
the
number of cyclones operating, and which cyclones are operating to adjust to
process
throughput, and to equalize wear on the individual cyclones from abrasive
slurry.
The battery of cyclones may include pneumatic as well as hydrocyclones.
The apparatus may include the sensors.
The sensors may include SONAR-based clamp-around flow meters configured
on the cyclones in the battery, e.g., on the overflow pipes.
Each SONAR-based clamp-around flow meter may be configured to respond to a
respective slurry stream fed into a respective cyclone in the battery, and
provide
respective signaling containing information about respective particle sizes of
respective
solids forming part of the respective slurry stream.
According to some embodiments, the present invention may take the form of a
method comprising steps for responding with at least one signal processor or
signal
processing module to signaling containing information about particle sizes of
solids
forming part of a slurry stream being fed with a common feed flow into a
battery of
.. cyclones; and determining with the at least one signal processor or signal
processing
module which combinations of cyclones in the battery produce overflow that has
undesirable particle size characteristics using a statistical algorithm or
technique, based
upon the signaling received.
The signal processor or signal processor module may take the form of a signal
processor and at least one memory including a computer program code, where the
signal processor and at least one memory are configured to cause the apparatus
to
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implement the functionality of the present invention, e.g., to respond to
signaling
received and to determine the combinations of cyclones in the battery that are
underperforming.
According to some embodiment, the present invention may take the form of
apparatus comprising means for responding to signaling containing information
about
particle sizes of solids forming part of a slurry stream being fed with a
common feed
flow into a battery of cyclones; and means for determining combinations of
cyclones in
the battery produce overflow that has undesirable particle size
characteristics using a
statistical algorithm or technique, based upon the signaling received,
consistent with
that set forth herein.
According to some embodiments of the present invention, the apparatus may
also take the form of a computer-readable storage medium having computer-
executable
components for performing the steps of the aforementioned method. The computer-
readable storage medium may also include one or more of the features set forth
above.
According to some embodiments of the present invention, the apparatus may
include, or forms part of, a classification stage in a mineral extraction
process.
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BRIEF DESCRIPTION OF THE DRAWING
The drawing includes Figures 1 - 5, which are not necessarily drawn to scale,
as
follows:
Figure 1A is a block diagram of a mineral extraction processing system in the
form of a copper concentrator that is known in the art.
Figure 1B is a block diagram showing typical processing stages of a mineral
extraction processing system that is known in the art.
Figure 2 is a block diagram showing a classification stage that is known in
the
art.
Figure 3A is a diagram showing a cyclone battery, sensors, a signal processor
and a remote computer processor that is known in the art.
Figure 3B is a diagram showing a cyclone having a sensor arranged on an
overflow pipe that is known in the art.
Figure 30 is a diagram showing an oversized detection system on a
hydrocyclone overflow line that is known in the art.
Figure 3D is a diagram showing a control room display of real-time cyclone
information that is known in the art.
Figure 4 shows a block diagram of apparatus, e.g., having a signal processor
or
signal processing module for implementing signal processing functionality
according to
some embodiments of the present invention.
Figure 5 shows a block diagram of a method, e.g., having steps for
implementing
the signal processing functionality according to some embodiments of the
present
invention.
CA 2922199 2019-06-20
DETAILED DESCRIPTION OF BEST MODE OF THE INVENTION
Summary of Basic Invention
In general, the present invention provides new and unique techniques to
optimize
the performance of individual cyclones operating in a battery of cyclones,
e.g., like the
.. hydrocyclone battery shown in Figures 2 and 3A.
In operation, sensing apparatus may be mounted on an overflow pipe of
individual hydrocyclones that monitors a characteristic of the slurry stream
such as
percentage of solids at or above a certain particle size, e.g. P80, or percent
solids
above 200 urn, or a number of impacts of large particles above 12mm. The
cyclones
may be mounted and operated as a group, called a battery, and are fed by a
common
feed flow, consistent with that set forth herein. Typically, between 60% and
90% of the
cyclones may be operated at one time, although the scope of the invention is
not
intended to be limited to any particular percentage of cyclones operated at
one time. By
way of example, operators may change the number of cyclones operating, and
which
cyclones are operating to adjust to process throughput, and to equalize wear
on the
individual cyclones from the abrasive slurry. Embodiments are also envisioned
in which
a controller controls, manages and/or changes the number of cyclones
operating, and
which cyclones are operating to adjust to process throughput, and to equalize
wear on
the individual cyclones from the abrasive slurry.
Individual cyclone signals may be sampled periodically and stored in a data
set
that can include other operational parameters such as which cyclones are open
at a
given time, a feed density, or a feed flow rate. By way of example, the
periodic
sampling may be implemented by using the sensor technology disclosed herein.
The data set may be analyzed over a sufficiently long time period to extract
statistically valid information as to which cyclones, and which combinations
of cyclones,
produce overflow that has undesirable particle size characteristics, such as
too large of
a particle size. In this manner, individual cyclones can be identified that
are performing
badly, e.g., for some physical reason attributable to that cyclone. By way of
example,
the data set may be analyzed to make such an extraction by using the signal
processing
.. technology disclosed herein.
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Additionally, and importantly with regard to the present invention, the data
set
may be analyzed to identify combinations of cyclones that produce overflow
streams
that have too coarse of a particle size, e.g., even though the individual
cyclones may
have no physical problems. By way of example, this is believed to be due to
the fact
that the physical pattern of the cyclones operating can affect the flow
pattern, e.g., in a
distribution box that feeds the individual cyclones, although the scope of the
invention is
not intended to be limited to any particular cause of such problems. For
example, the
physical pattern of the cyclones may include either the operating cyclones
being
adjacent to each other, or being formed or arranged in an alternating pattern.
The type
of pattern may affect the flow velocity in the distribution box that can lead
to non-uniform
velocities within the distribution box that produces a density and particle
size distribution
that is not the same to each cyclone. Again, by way of example, the data set
may be
analyzed to make such an identification by using the signal processing
technology
disclosed herein.
Examples of statistical techniques that may be applied may include:
determining
the average total flow of coarse particles for each combination of cyclones
operating;
determining the combinations most frequently used, or determining which
combinations
produce the most total coarse material over a reasonably long time interval.
This
information can provide operators with valuable information as to which
combinations of
.. cyclones to avoid, or preferentially use, to minimize the total amount of
coarse material
produced by the battery. By way of example, the data set may be analyzed to
make
such a statistical determination by using the signal processing technology
disclosed
herein to implement the associated signal processing functionality. The scope
of the
invention is not intended to limited to any particular time interval for
making any such
.. determination, e.g., which may include discrete predetermined time
intervals having
different lengths of time.
By way of example, the technique according to the present invention may be
applied to pneumatic as well as hydrocyclones, including those known.
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Figure 4
By way of example, Figure 4 shows apparatus generally indicated as 100, e.g.
having at least one signal processor or signal processing module 102 for
implementing
the signal processing functionality according to the present invention. In
operation, the
.. at least one signal processor or signal processing module 102 may be
configured at
least to:
respond to signaling Sin containing information about particle sizes of
solids forming part of a slurry stream being fed with a common feed flow into
a
battery of cyclones; and
determine which combinations of cyclones in the battery produce overflow
that has undesirable particle size characteristics using a statistical
algorithm or
technique, based upon the signaling received.
The signaling Sin may be received from sensors mounted on overflow pipes of
individual cyclones that monitor a characteristic of the slurry stream,
including a
percentage of solids at or above a certain particle size. The sensors may
include, or
take the form of, SONAR-based sensor, e.g., like the SONAR-based clamp-around
flow
meters 28, 38 configured on the overflow pipes 24, 34 of the cyclones 20, 30
in the
battery 12 shown in Figures 3A, 3B. In operation, each such SONAR-based clamp-
around flow meter may be configured to respond to a respective slurry stream
fed into a
respective cyclone in the battery, and provide respective signaling containing
information about respective particle sizes of respective solids forming part
of the
respective slurry stream. A person skilled in the art would appreciate and
understanding, e.g., after reading the instant patent application together
with that known
in the art, either how to implement suitable signaling processing
functionality to provide
such signaling containing such information using such a SONAR-based sensor, or
how
to adapt such a SONAR-based sensor to implement suitable signaling processing
functionality to provide such signaling containing such information, without
undue
experimentation.
The at least one signal processor or signal processing module 102 may also be
configured to determine which combinations of cyclones in the battery produce
overflow
that has undesirable particle size characteristics using the statistical
algorithm or
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technique, e.g., that may include determining the average total flow of coarse
particles
for each combination of cyclones operating; determining the combinations most
frequently used, and/or determining which combinations produce the most total
coarse
material over a long time interval. A person skilled in the art would
appreciate and
understanding, e.g., after reading the instant patent application together
with that known
in the art, how to implement suitable signaling suitable processing
functionality to make
one or more such determinations without undue experimentation.
The at least one signal processor or signal processing module 102 may be
configured to provide corresponding signaling Bout containing information
about which
combinations of cyclones in the battery produce overflow that has undesirable
particle
size characteristics. By way of example, the corresponding signaling Bout may
include,
or take the form of, control signaling to control the operation of the
battery, including
certain combinations of cyclones to avoid, or preferentially to use, to
minimize the total
amount of coarse material having the undesirable particle size characteristics
produced
by the battery.
The apparatus 100 may also include, e.g., other signal processor circuits or
components 104 that do not form part of the underlying invention, e.g.,
including
input/output modules, one or more memory modules, data, address and control
busing
architecture, etc. In operation, the at least one signal processor or signal
processing
module 102 may cooperation and exchange suitable data, address and control
signaling
with the other signal processor circuits or components 104 in order to
implement the
signal processing functionality according to the present invention. By way of
example,
the signaling Sin may be received by such an input module, provided along such
a data
bus and stored in such a memory module for later processing, e.g., by the at
least one
signal processor or signal processing module 102. After such later processing,
processed signaling resulting from any such determination may be stored in
such a
memory module, provided from such a memory module along such a data bus to
such
an output module, then provided from such an output module as the
corresponding
signaling Bout, e.g., by the at least one signal processor or signal
processing module
102.
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According to some embodiments of the present invention, the apparatus 100
may also include, e.g., one or more sensors, the battery of cyclones, etc.,
e.g.,
consistent with that set forth herein.
The SONAR-based Clamp-around Flow Meters
SONAR-based clamp-around flow meters for sensing and providing signaling
containing information about particle sizes of solids forming part of a slurry
stream being
fed with a common feed flow into a battery of cyclones are known in the art,
and/or may
be suitably adapted for sensing and providing such signaling, and the scope of
the
invention is not intended to be limited to any particular type or kind
thereof. By way of
example, such SONAR-based clamp-around flow meters, such as elements 28, 38 in
Figure 3A, are disclosed by way of example in whole or in part in United
States Patent
Nos. 7,165,464; 7,134,320; 7,363,800; 7,367,240; and 7,343,820. For example,
SONAR-based clamp-around flow meters may take the form of a SONAR-based
VF/GVF-100 meter, manufactured by the assignee of the present application. The
scope of the invention is also intended to include other types or kinds of
SONAR-based
VF/GVF meters that perform the same basic functionality of the aforementioned
SONAR-based VF/GVF meter as such functionality relates to implementing the
present
invention. The scope of the invention is also intended to include using the
SONAR-
based clamp-around flow meters alone or in combination with a density meter,
e.g. for
providing signaling containing information about the feed
density, disclosed by way of example in whole or in part in United States
Patent Nos.
7,165,464; 7,134,320; 7,363,800; 7,367,240; and 7,343,820.
The Signal Processor or Processor Control Module 100
The functionality of the signal processor or processor control module 100 may
be
implemented using hardware, software, firmware, or a combination thereof. In a
typical
software implementation, the processor module may include one or more
microprocessor-based architectures having a microprocessor, a random access
memory (RAM), a read only memory (ROM), input/output devices and control, data
and
CA 2922199 2019-10-16
address buses connecting the same, e.g., consistent with that shown in Figure
4, e.g.,
see element 104. A person skilled in the art would be able to program such a
microprocessor-based architecture(s) to perform and implement such signal
processing
functionality described herein without undue experimentation. The scope of the
invention is not intended to be limited to any particular implementation using
any such
microprocessor-based architecture or technology.
The Cyclone or Hydrocyclone 20, 30
The cyclone or hydrocyclone, e.g., like elements 20, 30 in Figures 3A and 3B,
are known in the art, and the scope of the invention is not intended to be
limited to any
particular type or kind thereof.
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The Classification Stage 10
By way of example, the present invention as it relates to the classification
stage
is described in relation to the mineral extraction processing system shown,
e.g., in
Figures 1A and 1B, which takes the form of a copper concentrator, although the
scope
5 of the invention is not intended to be limited to any particular type or
kind of mineral
process or mineral extraction processing system.
The classification stage 10 may also include one or more elements, devices,
apparatus or equipment that are known in the art, do not form part of the
underlying
invention, and are not disclosed herein or described in detail for that
reason.
10 The scope of the invention re classification stage and/or hydrocyclone
applications is not intended to be limited to the type or kind of mineral
being processed,
or the type of mineral process. By way of example, the scope of the invention
is
intended to include hydrocyclone applications include Molybdenum, Lead, Zinc,
Iron,
Gold, Silver, Nickel, Fluorite, Tantalum, Tungsten, Tin, Lithium, Coal, as
well as, e.g.
diamonds, etc.
Figure 5
Figure 5 shows a method generally indicated as 110 having steps 110a, 110b
and 110c for implementing the signal processing functionality, e.g., with at
least one
signal processor or signal processing module like element 102 in Figure 4,
according to
some embodiments of the present invention.
The method 100 may include a step 110a for responding with at least one signal
processor or signal processing module to signaling containing information
about particle
sizes of solids forming part of a slurry stream being fed with a common feed
flow into a
battery of cyclones; and a step 110b for determining with the at least one
signal
processor or signal processing module which combinations of cyclones in the
battery
produce overflow that has undesirable particle size characteristics using a
statistical
algorithm or technique, based upon the signaling received. The method 100 may
also
include a step 110c for providing corresponding signaling containing about
which
combinations of cyclones in the battery produce overflow that has undesirable
particle
size characteristics.
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The method may also include one or more steps for implementing other features
of the present invention set forth herein, including steps for making the
various
determinations associated with the statistical algorithm or technique set
forth herein.
SONAR-Based Flow Monitoring
As one skilled in the art would appreciate, SONAR array-based flow
measurement technology was introduced into the mineral processing industry
over five
years ago, and has since demonstrated significant usefulness and value in many
difficult and critical flow monitoring applications. This robust non-invasive
technology
has become the standard for many companies in certain applications. The reader
is
referred to the aforementioned patent application serial no. 13/389,546 for a
more
comprehensive discussion of the same, e.g., including that set forth in
relation to
Figures 13-19 therein.
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Applications Re Other Industrial Processes
By way of example, the present invention is described in relation to, and part
of,
a mineral extraction processing system for extracting minerals from ore.
However, the
scope of the invention is intended to include other types or kinds of
industrial processes,
including any mineral process, such as those related to processing substances
or
compounds that result from inorganic processes of nature and/or that are mined
from
the ground, as well as including either other extraction processing systems or
other
industrial processes, where the sorting, or classification, of product by size
is critical to
overall industrial process performance.
The Scope of the Invention
While the invention has been described with reference to an exemplary
embodiment, it will be understood by those skilled in the art that various
changes may
be made and equivalents may be substituted for elements thereof without
departing
.. from the scope of the invention. In addition, may modifications may be made
to adapt a
particular situation or material to the teachings of the invention without
departing from
the essential scope thereof. Therefore, it is intended that the invention not
be limited to
the particular embodiment(s) disclosed herein as the best mode contemplated
for
carrying out this invention.
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