Transforming operations using AI technology | Pit & Quarry

Oct 15, 2024

Crushing and screening processes are critical to the production of quality material in the mining and aggregate industries.

Traditionally, these processes have been energy-intensive and labor-heavy, contributing to high costs and substantial environmental footprints. Advancements in machine vision AI, however, combined with innovations in edge computing and real-time data analysis, can enhance sustainability in these processes by improving efficiency, reducing energy consumption and minimizing waste.

Mining is undergoing a digital transformation, and at the heart of this revolution is machine vision AI technology. As the industry grapples with increasing pressure to reduce its environmental impact, optimize energy use and ensure operational efficiency, this cutting-edge technology can redefine how critical processes like comminution are managed.

For decades, the comminution process – one where large quantities of blasted rock are fed into crushers and grinders – has been energy-intensive, costly and risky. Let’s explore the core challenges facing the mining and aggregate sectors, and how machine vision AI can serve as an industry-changing solution.

1. Energy efficiency and carbon emissions. Comminution represents a staggering 50 percent of a mine’s total energy consumption. Globally, this process accounts for more than 3 percent of the world’s total electricity use.

Given the scale of operations, energy consumption is not only an operational cost, but a key driver of carbon emissions. Mining companies are under increasing pressure from governments, investors and society to reduce their carbon footprint and improve sustainability.

2. Rising operating expenses. Energy isn’t the only cost driver. Comminution processes account for around 10 percent of a mine’s total operating expenses.

As the mining sector deals with lower-grade deposits, fluctuating commodity prices and declining investment from retail investors, achieving economic viability is more challenging. The industry must seek ways to cut costs without compromising productivity.

3. Safety risks from foreign objects. Foreign objects such as metal, plastic and rubber can unexpectedly enter the comminution circuit. These objects pose serious risks, causing equipment blockages or damage that can halt operations for days at a time. They also can result in millions of dollars in lost revenue.

So, the ability to detect and remove these objects in real-time is crucial to maintain operational continuity.

Machine vision AI is revolutionizing crushing and screening by automating the detection and measurement of particle sizes, which are key in optimizing the efficiency of crushing and screening equipment.

At the heart of this transformation are systems that utilize 3D stereo cameras, edge computing and cloud platforms to monitor material flow in real-time. By installing a camera and sensor array over the hauling and material handling circuit, machine vision AI continuously monitors the size, shape, color and density of the materials being processed.

This data-driven approach significantly enhances sustainability in several ways.

Crushing and screening are energy-intensive processes within mining operations.

One factor that impacts energy consumption is the particle size distribution of the ore being processed. Traditional methods for determining ore size, such as manual screening, are time-consuming and prone to error. Machine vision AI systems, meanwhile, enable real-time monitoring of particle size distribution, allowing for immediate adjustments to crusher settings and, thus, optimizing energy use.

By precisely detecting ore granularity through cameras and image processing, operators can maintain optimal conditions for energy efficiency. Machine vision systems allow operators to optimize crusher parameters based on real-time data, minimizing energy use while maintaining high throughput.

The ability to monitor particle size in real-time ensures crushers operate at the most efficient settings, preventing over-crushing and reducing energy waste.

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