
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
Fields of research
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
2021
Journal Article
An alternative strategy to compensate for screw wear in gravity induced stirred mills
Esteves, Priscila M., Mazzinghy, Douglas B., Hilden, Marko M., Yahyaei, Mohsen, Powell, Malcolm S. and Galery, Roberto (2021). An alternative strategy to compensate for screw wear in gravity induced stirred mills. Powder Technology, 379, 384-392. doi: 10.1016/j.powtec.2020.10.075
2021
Journal Article
An improved method for grinding mill filling measurement and the estimation of load volume and mass
Hilden, Marko M., Powell, Malcolm S. and Yahyaei, Mohsen (2021). An improved method for grinding mill filling measurement and the estimation of load volume and mass. Minerals Engineering, 160 (1) 106638, 1-9. doi: 10.1016/j.mineng.2020.106638
2020
Journal Article
Mechanistic modeling and simulation of a batch vertical stirred mill
Oliveira, A. L.R., Rodriguez, V. A., de Carvalho, R. M., Powell, M. S. and Tavares, L. M. (2020). Mechanistic modeling and simulation of a batch vertical stirred mill. Minerals Engineering, 156 106487, 106487. doi: 10.1016/j.mineng.2020.106487
2019
Conference Publication
A method to evaluate the impact of stockpile size segregation on the performance of SAG mills
Ye, Ziming, Yahyaei, Mohsen, Hilden, Marko and Powell, Malcolm (2019). A method to evaluate the impact of stockpile size segregation on the performance of SAG mills. SAG Conference 2019, Vancouver, Canada, 22–26 September 2019.
2019
Conference Publication
How our clients will drive the need to slash energy use in mining
Powell, M. (2019). How our clients will drive the need to slash energy use in mining. 26th International Mining Congress and Exhibition of Turkey, Antalya, Turkey, 16-19 April 2019. Antalya, Turkey: Baski.
2019
Journal Article
Applying Fréchet distance to evaluate the discrepancy of product size distribution between single particle and monolayer multi-particle breakage
Yu, P., Xie, W., Liu, L. X. and Powell, M. S. (2019). Applying Fréchet distance to evaluate the discrepancy of product size distribution between single particle and monolayer multi-particle breakage. Powder Technology, 344, 647-653. doi: 10.1016/j.powtec.2018.12.043
2019
Conference Publication
An assessment of the energy efficiency and operability of the world's largest autogenous grinding mills at Boliden's Aitik mine
McElroy, Adam, Powell, Malcolm, Tillberg, Jan, Hilden, Marko, Yahyaei, Mohsen, Linna, Matti and Johansson, Anna (2019). An assessment of the energy efficiency and operability of the world's largest autogenous grinding mills at Boliden's Aitik mine. SAG CONFERENCE 2019, Vancouver, BC, Canada, 22 - 26 September 2019.
2019
Conference Publication
A dynamic model for materials storage to model size segregation
Ye, Ziming, Yahyaei, Mohsen, Hilden, Marko and Powell, Malcolm (2019). A dynamic model for materials storage to model size segregation. 13th International Conference on Bulk Materials Storage, Handling and Transportation, Surfers Paradise, QLD Australia, 9-11 July 2019. Barton, ACT Australia: Engineers Australia.
2019
Conference Publication
Development of a laboratory test to quantify the size segregation in stockpiles
Ye, Ziming, Yahyaei, Mohsen, Hilden, Marko and Powell, Malcolm (2019). Development of a laboratory test to quantify the size segregation in stockpiles. 16th European Symposium on Comminution & Classification (ESCC 2019), Leeds, United Kingdom, 2-4 September 2019.
2019
Conference Publication
The new suite of breakage characterisation tests
Powell, M. S., Bonfils, B., Ballantyne, G. R., Yahyaei, M. and Hilden, M. M. (2019). The new suite of breakage characterisation tests. 29th International Mineral Processing Congress, IMPC 2018, Moscow, Russia, 17- 21 September, 2018. Montreal, Canada: Canadian Institute of Mining, Metallurgy and Petroleum.
2019
Conference Publication
Advanced mine-to-mill used to unlock SABC capacity at the Barrick Cortez mine
Powell, Malcolm, Bozbay, S., Kanchibotla, S., Bonfils, B., Musunuri, A., Jokovic, V., Hilden, M., Young, J. and Yalcin, E. (2019). Advanced mine-to-mill used to unlock SABC capacity at the Barrick Cortez mine. International Conference on Autogenous Grinding, Semi-autogenous Grinding and High Pressure Grinding Roll Technology, Vancouver, BC, Canada, 22-26 September 2019.
2019
Conference Publication
Qualitative evaluation of the grinding efficiency of a gravity induced stirred mill using the size specific energy approach
Esteves, Priscila, Mazzinghy, Douglas, Hilden, Marko, Yahyaei, Mohsen, Powell, Malcolm and Galery, Roberto (2019). Qualitative evaluation of the grinding efficiency of a gravity induced stirred mill using the size specific energy approach. 16th European Symposium on Comminution and Classification (ESCC 2019), Leeds, United Kingdom, 2-4 September 2019.
2019
Conference Publication
Initial applyication of a dynamic, mechanistic mill model
Bonfils, B. and Powell, M. S. (2019). Initial applyication of a dynamic, mechanistic mill model. 29th International Mineral Processing Congress, IMPC 2018, Moscow, Russia, 15-21 September 2018. Montreal, Canada: Canadian Institute of Mining, Metallurgy and Petroleum.
2019
Conference Publication
Production improvement opportunities in comminution circuits
Yahyaei, Mohsen and Powell, Malcolm (2019). Production improvement opportunities in comminution circuits. 14th AusIMM Mill Operators' Conference 2018, Brisbane, Australia, 29-31 August 2019. Carlton VIC Australia: The Australasian Institute of Mining and Metallurgy.
2018
Journal Article
Evolution of a generic, dynamic and multicomponent tumbling mill model structure incorporating a wide-range 4D appearance function
Yu, P., Xie, W., Liu, L. X., Hilden, M. M. and Powell, M. S. (2018). Evolution of a generic, dynamic and multicomponent tumbling mill model structure incorporating a wide-range 4D appearance function. Powder Technology, 339, 396-407. doi: 10.1016/j.powtec.2018.08.016
2018
Conference Publication
Advanced mine to mill application at the Barrick Cortez mine
Powell, Malcolm, Kanchibotla, Sarma, Jokovic, Vladimir, Hilden, Marko, Bonfils, Benjamin, Musunuri, Anand, Moyo, Pamela, Yu, Samuel, Young, Jace, Yaroshak, Paul, Yalcin, Emrah and Gorain, Barun (2018). Advanced mine to mill application at the Barrick Cortez mine. The 14th AusIMM Mill Operator’s Conference, Brisbane, QLD Australia, 29-31 August 2018. Brisbane, QLD Australia: AusIMM.
2017
Journal Article
Simulating product size distribution of an industrial scale VertiMill® using a time-based population balance model
Hasan, Maruf, Palaniandy, Sam, Hilden, Marko and Powell, Malcolm (2017). Simulating product size distribution of an industrial scale VertiMill® using a time-based population balance model. Minerals Engineering, 127, 312-317. doi: 10.1016/j.mineng.2017.11.007
2017
Journal Article
Evolution of impact breakage characterisation: re-defining t-family relationship
Ballantyne, Grant, Bonfils, Benjamin and Powell, Malcolm (2017). Evolution of impact breakage characterisation: re-defining t-family relationship. International Journal of Mineral Processing, 168, 126-135. doi: 10.1016/j.minpro.2017.10.001
2017
Journal Article
A geometrical texture model for multi-mineral liberation prediction
Hilden, Marko M. and Powell, Malcolm S. (2017). A geometrical texture model for multi-mineral liberation prediction. Minerals Engineering, 111, 25-35. doi: 10.1016/j.mineng.2017.04.020
2017
Journal Article
Calculating breakage parameters of a batch vertical stirred mill
Hasan, Maruf, Palaniandy, Sam, Hilden, Marko and Powell, Malcolm (2017). Calculating breakage parameters of a batch vertical stirred mill. Minerals Engineering, 111, 229-237. doi: 10.1016/j.mineng.2017.06.024
Funding
Past funding
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
-
2024
Doctor Philosophy
Development of a novel ore characterisation method for the precise measurement of practical minimum comminution energy
Principal Advisor
Other advisors: Dr Dion Weatherley, Professor Mohsen Yahyaei
-
2017
Doctor Philosophy
Modelling and simulation approaches for exploiting multi-component characteristics of ores in mineral processing circuits
Principal Advisor
Other advisors: Dr Marko Hilden
-
2016
Doctor Philosophy
Development of a correlation between mineralogy, rock strength measures, and breakage of Copper Porphyries
Principal Advisor
-
2014
Master Philosophy
Grinding of Itabirite Iron Ore in Autogenous and Semi-Autogenous Mills.
Principal Advisor
-
2014
Master Philosophy
Quantifying the Influence of Liner Wear on SAG Mill Performance
Principal Advisor
Other advisors: Dr Marko Hilden
-
2023
Doctor Philosophy
Techno-Economic Multicomponent Analysis of Comminution Using Minerals Processing Simulators
Associate Advisor
Other advisors: Professor Mohsen Yahyaei
-
2022
Doctor Philosophy
DEVELOPING A 3-D DYNAMIC STOCKPILE/BIN MODEL WITH SIZE SEGREGATION FOR DRY COMMINUTION CIRCUITS
Associate Advisor
Other advisors: Dr Marko Hilden, Professor Mohsen Yahyaei
-
2020
Doctor Philosophy
The impact of classification efficiency on comminution performance and flotation recovery
Associate Advisor
Other advisors: Associate Professor Kym Runge
-
2017
Master Philosophy
Development of a standard methodology for energy efficiency measurement in comminution processes
Associate Advisor
-
-
2017
Doctor Philosophy
New Approach for Characterising a Breakage Event as a Multi-stage Process
Associate Advisor
Other advisors: Professor Mohsen Yahyaei
-
2016
Doctor Philosophy
Process Modelling of Gravity Induced Stirred Mills
Associate Advisor
Other advisors: Dr Marko Hilden
-
2016
Master Philosophy
The effects of high voltage pulse treatment on ore characteristics and separation performances of a porphyry copper ore
Associate Advisor
Other advisors: Dr Marko Hilden
-
2016
Master Philosophy
Application of the grindcurve methodology to AG/SAG mill control
Associate Advisor
Other advisors: Dr Marko Hilden
-
2015
Master Philosophy
Developing an abrasion characterisation test for measuring superficial breakage in comminution
Associate Advisor
Other advisors: Professor Mohsen Yahyaei
-
-
2014
Doctor Philosophy
A structured approach for integrating sustainable development principles into the decision-making processes at minerals processing operations
Associate Advisor
-
2013
Doctor Philosophy
Development of a Multi-Component Model Structure for Autogenous and Semi-Autogenous Mills
Associate Advisor
-
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: