Skip to menu Skip to content Skip to footer
Emeritus Professor Malcolm Powell
Emeritus Professor

Malcolm Powell

Email: 

Overview

Background

Malcolm has applied fundamental comminution research to design and process improvement on over 70 mines worldwide during 40 years at Mintek, UCT, Professor of comminution at the JKMRC in Australia, and through private research companies. His work is published in over 240 papers and has been presented in as many conferences worldwide. Malcolm collaborates extensively, with close compatriots on 5 continents forming the Global Comminution Collaborative (GCC) – providing an expert research and consulting base covering the full comminution process chain. Malcolm provides on-site experiential training and site reviews to empower mine staff to upgrade the productivity and their skills. This is supplemented with formal training workshops on liner design, comminution and Advanced Mine to Mill. Malcolm’s research vision is of integrated total process simulation as a tool for innovation – linking geology, mining, energy and size reduction, gangue rejection and recovery into flexible process design and process optimisation.

Malcolm supervises research students and runs three companies dedicated to advancing cutting edge technology into the mining industry. These focus around operation-relevant training; advanced mill liner design using DEM modelling; mechanistic mill modelling; introducing the latest tools into daily process control; operationalising advanced mine-to-mill implementation; and development of step-change reduction in comminution energy.

Availability

Emeritus Professor Malcolm Powell is:
Available for supervision
Media expert

Qualifications

  • Bachelor of Science, University of Kwazulu Natal
  • Doctor of Philosophy, University of Cape Town

Research interests

  • Flexible circuits

    “FlexiCircuits leverage ore variability to maximise resource utilisation”. The focus of flexible circuits is to investigate processing options that provide extra capacity through sophistication rather than scale. This requires a combination of smart ore characterisation, economic modelling and innovative processing plant design. Flexible mineral processing circuits can respond to variations in feed characteristics (competence, size distribution, grade and deleterious components) and processing requirements by varying the processing route in order to maximise recovery within energy usage limitations. The application is via utilising today’s equipment while enabling the uptake of tomorrows technology.

  • Applying fundamental research to applied outputs

    Applied outputs are based on the development of mechanistically correct but practical and robust process models. Interests cover: mill liner design; SAG mill modelling and control; the unified comminution model (UCM); ore characterisation for multi-component modelling; applied comminution process review, modelling and improvement.

Research impacts

An H index 27 with about 150 article downloads per week.

Malcolm places a strong emphasis on presenting at conferences, as a pathway to connecting research outcomes to other researchers, and importantly to encourage industry uptake of the latest technology arising from research.

Recent process reviews: In 2019 demonstrated and provided the technical pathway to increase production by between 10 and 20% on three mines (Las Bambas, Peru; New gold and Voisey’s bay, Canada). At Barrick Cortez demonstrated a 16% increase in mill throughput capacity (Powell et al. AusIMM mill operators conference 2018 and SAG conference 2019), and again in 2020 for a new ore body. Anglo American Platinum Mogalakwena crushing circuit: capacity increased by 20% based on recommendations of a GCC review and simulations, worth about $100M per annum (Powell et al, SAG conference 2011). Increased mill throughput at Cadia of 10% over a period of liner life, translating to 3% over liner life, a value of over $20M per annum (Bird et al., SAG conference, 2011). Navachab Ball scats removal: a step change of 9% in mill throughput (Powell and Smit, SAG conference 2001), which drove an industry-wide upgrade to grinding ball quality in Southern Africa.

Liner design: Increases in liner life of over 50% on many mills, worth $0.3-1.5M per annum on single mills. Liner redesign Pustynnoye mine, Kahzakstahn: increased liner life by 50% and mill throughput by 20% (Powell et al, AusIMM.MillOps, 2018).

MillTraj liner design software: with over 200 licences with half the world liner suppliers the use of this software has propagated liner life and mill performance improvement worldwide.

Works

Search Professor Malcolm Powell’s works on UQ eSpace

204 works between 2001 and 2024

1 - 20 of 204 works

Featured

2012

Journal Article

Human factors in control room operations in mineral processing: Elevating control from reactive to proactive

Li, Xilin, Powell, Malcolm and Horberry, Tim (2012). Human factors in control room operations in mineral processing: Elevating control from reactive to proactive. Journal of Cognitive Engineering and Decision Making, 6 (1), 88-111. doi: 10.1177/1555343411432340

Human factors in control room operations in mineral processing: Elevating control from reactive to proactive

Featured

2012

Conference Publication

Step change - a staircase rather than a giant leap

Powell, M. S. and Mainza, A. N. (2012). Step change - a staircase rather than a giant leap. XXVI International Mineral Processing Congress - IMPC 2012, New Delhi, India, 24-28 September 2012. New Delhi, India: International Mineral Processing Congress.

Step change - a staircase rather than a giant leap

Featured

2011

Conference Publication

Adapting mill control to account for liner wear on the Cadia 40ft mill.

Bird, Matt, Powell, Malcolm, Robertson, Jason, Hilden, Marko and Franke, Jochen (2011). Adapting mill control to account for liner wear on the Cadia 40ft mill.. International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Rolls Technology 2011, Vancouver BC, Canada, 25-28 September, 2011. Canada: Canadian Institute of Mining and Metallurgy.

Adapting mill control to account for liner wear on the Cadia 40ft mill.

Featured

2011

Conference Publication

Integrating liner profile evolution and mill performance with 3D DEM modelling

Weerasekara, Nirmal, Powell, Malcolm, Franke, J. and Favier, J. (2011). Integrating liner profile evolution and mill performance with 3D DEM modelling. International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Rolls Technology 2011, Vancouver, BC, Canada, 25-28 September, 2011. Canada: Canadian Institute of Mining and Metallurgy.

Integrating liner profile evolution and mill performance with 3D DEM modelling

Featured

2011

Conference Publication

The strengths of SAG and HPGR in flexible circuit designs

Powell, Malcolm, Benzer, Hakan and Mainza, Aubrey (2011). The strengths of SAG and HPGR in flexible circuit designs. International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Rolls Technology 2011, Vancouver BC, Canada, 25-28 September, 2011. Canada: Canadian Institute of Mining and Metallurgy.

The strengths of SAG and HPGR in flexible circuit designs

Featured

2010

Conference Publication

Exploring the breakage environment in mills with discrete element methods

Weerasekara, Nirmal and Powell, Malcolm (2010). Exploring the breakage environment in mills with discrete element methods. International Mineral Processing Congress 2010, Brisbane, Qld, Australia, 6-10 September, 2010. Carlton, VIC, Australia: Australasian Institute of Mining and Metallurgy.

Exploring the breakage environment in mills with discrete element methods

Featured

2009

Conference Publication

Beyond mine-to-mill: Circuit design for energy efficient resource utilisation.

Powell, M. and Bye, A. (2009). Beyond mine-to-mill: Circuit design for energy efficient resource utilisation.. Tenth Mill Operators' Conference, Adelaide, SA, 12-14 October, 2009. Carlton, VIC: AusIMM.

Beyond mine-to-mill: Circuit design for energy efficient resource utilisation.

Featured

2009

Journal Article

Applying grinding curves to mill operation and optimisation

Powell, M. S., van der Westhuizen, A. P. and Mainza, A. N. (2009). Applying grinding curves to mill operation and optimisation. Minerals Engineering, 22 (7-8), 625-632. doi: 10.1016/j.mineng.2009.01.008

Applying grinding curves to mill operation and optimisation

Featured

2007

Journal Article

The future of comminution modelling

Powell, M. S. and Morrison, R. D. (2007). The future of comminution modelling. International Journal of Mineral Processing, 84 (1-4), 228-239. doi: 10.1016/j.minpro.2006.08.003

The future of comminution modelling

Featured

2006

Conference Publication

Slurry pooling and transport issues in SAG mills

Powell, M. S. and Valery, W. (2006). Slurry pooling and transport issues in SAG mills. International autogenous and semiautogenous grinding technology, Vancouver, Canada, 24-27 September, 2006. Vancouver, Canada: University of British Columbia, Dept. of Mining Engineering.

Slurry pooling and transport issues in SAG mills

Featured

2004

Journal Article

Improved experimental tracking techniques for validating discrete element method simulations of tumbling mills

Govender, I., McBride, A. T. and Powell, M. S. (2004). Improved experimental tracking techniques for validating discrete element method simulations of tumbling mills. Experimental Mechanics, 44 (6), 593-607. doi: 10.1177/0014485104048333

Improved experimental tracking techniques for validating discrete element method simulations of tumbling mills

2024

Journal Article

Energy-based modelling of single-particle breakage by slow compression

Campos, Túlio M., Andersson, Caroline, Evertsson, Magnus, Powell, Malcolm and Tavares, Luís Marcelo (2024). Energy-based modelling of single-particle breakage by slow compression. Minerals Engineering, 208 108585. doi: 10.1016/j.mineng.2024.108585

Energy-based modelling of single-particle breakage by slow compression

2023

Journal Article

Novel size segregation indices for multi-sized particle stockpiles

Ye, Z., Yahyaei, M., Hilden, M. and Powell, M.S. (2023). Novel size segregation indices for multi-sized particle stockpiles. Minerals Engineering, 201 108165, 108165. doi: 10.1016/j.mineng.2023.108165

Novel size segregation indices for multi-sized particle stockpiles

2023

Journal Article

Comminution and Classification as Important Process Steps for the Circular Production of Lithium Batteries

Kwade, Arno, Möller, Marcel, Müller, Jannes, Hesselbach, Jutta, Zellmer, Sabrina, Doose, Stefan, Mayer, Julian, Michalowski, Peter, Powell, Malcolm and Breitung-Faes, Sandra (2023). Comminution and Classification as Important Process Steps for the Circular Production of Lithium Batteries. KONA Powder and Particle Journal, 2023 (40) 2023006, 50-73. doi: 10.14356/kona.2023006

Comminution and Classification as Important Process Steps for the Circular Production of Lithium Batteries

2022

Conference Publication

A standardised method for the precise quantification of practical minimum comminution energy

Ali, S., Powell, M. S., Yahyaei, M., Weatherley, D. K. and Ballantyne, G. R. (2022). A standardised method for the precise quantification of practical minimum comminution energy. IMPC Asia-Pacific Conference 2022, Melbourne, VIC Australia, 22–24 August 2022. Carlton, VIC Australia: AusIMM.

A standardised method for the precise quantification of practical minimum comminution energy

2022

Journal Article

Trialling one-part geopolymer production including iron ore tailings as fillers

Mazzinghy, Douglas B., Figueiredo, Ricardo A.M., Parbhakar-Fox, Anita, Yahyaei, Mohsen, Vaughan, James and Powell, Malcolm S. (2022). Trialling one-part geopolymer production including iron ore tailings as fillers. International Journal of Mining, Reclamation and Environment, 36 (5), 1-12. doi: 10.1080/17480930.2022.2047271

Trialling one-part geopolymer production including iron ore tailings as fillers

2021

Journal Article

A consolidated summary on the evolution of a dynamic tumbling mill model

Yu, P., Xie, W., Liu, L. X., Hilden, M. and Powell, M. S. (2021). A consolidated summary on the evolution of a dynamic tumbling mill model. Powder Technology, 391, 173-183. doi: 10.1016/j.powtec.2021.06.017

A consolidated summary on the evolution of a dynamic tumbling mill model

2021

Journal Article

The effect of screen versus cyclone classification on the mineral liberation properties of a polymetallic ore

Frausto, J.J., Ballantyne, G.R., Runge, K., Powell, M.S., Wightman, E.M., Evans, C.L., Gonzalez, P. and Gomez, S. (2021). The effect of screen versus cyclone classification on the mineral liberation properties of a polymetallic ore. Minerals Engineering, 169 106930, 1-9. doi: 10.1016/j.mineng.2021.106930

The effect of screen versus cyclone classification on the mineral liberation properties of a polymetallic ore

2021

Journal Article

The double wheel breakage test

Bueno, Marcos, Torvela, Janne, Chandramohan, Rajiv, Chavez Matus, Tabatha, Liedes, Toni and Powell, Malcolm (2021). The double wheel breakage test. Minerals Engineering, 168 106905. doi: 10.1016/j.mineng.2021.106905

The double wheel breakage test

2021

Journal Article

Comparing strategies for grinding itabirite iron ores in autogenous and semi-autogenous pilot-scale mills

Rodrigues, Armando F.d.V., Delboni, Homero, Powell, Malcolm S. and Tavares, Luis Marcelo (2021). Comparing strategies for grinding itabirite iron ores in autogenous and semi-autogenous pilot-scale mills. Minerals Engineering, 163 106780. doi: 10.1016/j.mineng.2021.106780

Comparing strategies for grinding itabirite iron ores in autogenous and semi-autogenous pilot-scale mills

Funding

Past funding

  • 2019 - 2020
    Project No.7 Cyclone classification
    Weir Minerals Australia Ltd
    Open grant
  • 2019 - 2020
    P3-007 Validation of mass balance and model calibration in IES (P9Q AR)
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2018 - 2019
    Grindcurve survey of the Aitik grinding circuit
    Boliden Mineral AB
    Open grant
  • 2018
    DEM Modelling of stirred mill prototype and alternative stirrer designs
    Weir Minerals Australia Ltd
    Open grant
  • 2018
    Process Improvement Toolbox - Technology uptake and embedding (Project 3)
    Anglo Operations Limited
    Open grant
  • 2017 - 2021
    Barrick Cortez Mine to Mill Digitization Project
    Barrick Gold Corporation (Canada)
    Open grant
  • 2017 - 2020
    Translating Research to Industry Tools: Validated Multi-Component Mineral Processing Simulator (AMP9Q)
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2016 - 2017
    Stress intensity in stirred mill
    Weir Minerals Australia Ltd
    Open grant
  • 2015 - 2022
    Newcrest research higher degree student projects
    NewCrest Mining Limited
    Open grant
  • 2015
    Cadia throughput study
    NewCrest Mining Limited
    Open grant
  • 2015 - 2018
    Relationship Management
    Weir Minerals Australia Ltd
    Open grant
  • 2015 - 2019
    Expansion of the energy curve to achieve critical mass of copper and gold mines internationally
    CEEC International Limited
    Open grant
  • 2014
    Improving Liner Design for Efficiency and Life
    Russell Mineral Equipment Pty Ltd
    Open grant
  • 2014 - 2015
    V2 sag model
    JKTech Pty Ltd
    Open grant
  • 2012 - 2018
    Anglo American Centre for Sustainable Comminution
    Anglo Operations Proprietary Limited
    Open grant
  • 2012 - 2014
    Coarse Liberation Circuits - Phase 1
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2012 - 2016
    AMIRA P9P - The optimisation of mineral processing by modelling and simulation 2012-2015
    AMIRA International Limited
    Open grant
  • 2012
    Telfer Resource Upgrade Initiative
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2011 - 2012
    Exploration of Cadia Valley Operations (CVO) Expansion
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2011 - 2012
    Anglo American's Water: Zero Net Water Consumption (CRC ORE project subcontract)
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2011 - 2015
    Collaborative development of stirred milling technology
    Metso Minerals (Australia) Limited
    Open grant
  • 2011 - 2012
    Experimental and Computational Modelling of the Rio Tinto Drum Scrubber
    Technological Resources Pty Limited
    Open grant
  • 2011 - 2012
    Mogalakena North (MN) Dry section Capacity Upgrade
    Anglo Platinum Limited
    Open grant
  • 2011 - 2012
    Flexible Circuits
    Cooperative Research Centre for Optimising Resource Extraction Ltd
    Open grant
  • 2011
    Characterisation of breakage samples in context of shape parameters down to a 10mm size using a QICPIC optical sizer from SYMPATEC
    UQ Major Equipment and Infrastructure
    Open grant
  • 2011
    Sustainable Minerals Institute Data Analysis and Visualisation Laboratory
    UQ Major Equipment and Infrastructure
    Open grant
  • 2010 - 2011
    Reduction of Mill Energy Utilisation Through Liner Shape Optimisation
    Scanalyse Pty Ltd
    Open grant
  • 2010
    Gas gun upgrade
    UQ Major Equipment and Infrastructure
    Open grant
  • 2009
    Novel studies of size and shape-based effects in mineral processing using a Camsizer
    UQ School/Centre Co-Funding
    Open grant
  • 2008 - 2009
    Flotation of coarse particles
    CRC for Sustainable Resource Processing
    Open grant
  • 2008 - 2010
    CSRP Comminution Program Leadership
    CRC for Sustainable Resource Processing
    Open grant
  • 2008 - 2009
    HPGR Triple Pass HPGR Circuit Concept
    CRC for Sustainable Resource Processing
    Open grant
  • 2008
    Demonstration of banana screen modelling capabilities
    CRC for Sustainable Resource Processing
    Open grant
  • 2008 - 2010
    Eco-efficient liberation and communition
    CRC for Sustainable Resource Processing
    Open grant
  • 2008 - 2011
    The optimisation of Mineral Processing by Modelling and Simulation 2008 - 2011
    AMIRA International Limited
    Open grant

Supervision

Availability

Emeritus Professor Malcolm Powell is:
Available for supervision

Before you email them, read our advice on how to contact a supervisor.

Available projects

  • Mechanistic mill modelling

    Steppping modelling of mineral processing into the digita era, by utilising high-end computing to enable dynamic process simulation in real time.

    The models are built on a foundation of sund physics including: rock fracture for a continuum of ore strength properties adn matching the modes found in comminution devices, material transport, diffusive flow in a packed bed of particles, collision energy spectra, pulp and solids discharge functions. Computational tools of CFD and DEM are used to study the internal grinding enviroment adn provide the 'experimental' data upon which to claibrate analytic solutions that can be solved in real-time with numerical techniques. These are calibrated to pilot tests and ultimately large-scale production equipment.

    The outcome will be a dynamic, mechanistic model, that can be used for desiogn, optimisaton studies, and to support on-line control. Such an outcome will be trasnformative to the mining industry in terms of advaning the processing efficiency and reducing the environmental impact of mining while ensuring its continued viability in providing essential resources to society.

    An applicant should be inspired by science being applied to industry, be strong in applied mathematical modelling and computing, and willing to develop a comprehensive set of new skills.

Supervision history

Completed supervision

Media

Enquiries

Contact Emeritus Professor Malcolm Powell directly for media enquiries about:

  • Comminution in mining
  • DEM modelling
  • Mill grinding equipment
  • Mill liners
  • Mineral processing
  • Mining
  • Mining equipment

Need help?

For help with finding experts, story ideas and media enquiries, contact our Media team:

communications@uq.edu.au