
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
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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.
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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
2017
Journal Article
The development of the wide-range 4D appearance function for breakage characterisation in grinding mills
Yu, P., Xie, W., Liu, L. X. and Powell, M. S. (2017). The development of the wide-range 4D appearance function for breakage characterisation in grinding mills. Minerals Engineering, 110, 1-11. doi: 10.1016/j.mineng.2017.04.004
2017
Journal Article
Assessment of hydrocyclone operation in gravity induced stirred mill circuit
Palaniandy, Samayamutthirian, Mohsen Yahyaei and Powell, Malcolm (2017). Assessment of hydrocyclone operation in gravity induced stirred mill circuit. Minerals Engineering, 108, 83-92. doi: 10.1016/j.mineng.2017.01.002
2017
Journal Article
Analytical solution for the dynamic model of tumbling mills
Yu, Ping, Xie, Weiguo, Liu, Lian X. and Powell, Malcolm S. (2017). Analytical solution for the dynamic model of tumbling mills. Powder Technology, 337, 111-118. doi: 10.1016/j.powtec.2017.04.035
2017
Journal Article
HPGR simulation from piston-die tests with an itabirite ore
Benzer, Hakan, Dündar, Hakan, Altun, Okay, Tavares, Luis Marcelo Marques, Powell, Malcolm, Mazzinghy, Douglas Batista and Russo, José Francisco Cabello (2017). HPGR simulation from piston-die tests with an itabirite ore. Revista Escola de Minas, 70 (1), 99-107. doi: 10.1590/0370-44672015700058
2017
Conference Publication
The Impact of Classification Efficiency on Comminution and Flotation Circuit Performance
Frausto, J. J., Ballantyne, G. R., Runge, K., Powell, M. S. and Cruz, R. (2017). The Impact of Classification Efficiency on Comminution and Flotation Circuit Performance. AusIMM Metallurgical Plant Design and Operating Strategies (MetPlant) Conference, Perth, Australia, 11-12 September 2017. Carlton South, VIC Australia: AusIMM.
2017
Journal Article
Investigating the effect of applied strain rate in a single breakage event
Saeidi, Fatemeh, Yahyaei, Mohsen, Powell, Malcolm and Tavares, Luis Marcelo (2017). Investigating the effect of applied strain rate in a single breakage event. Minerals Engineering, 100, 211-222. doi: 10.1016/j.mineng.2016.09.010
2017
Conference Publication
Bivariate population balance equations for progressive weakening and fragmentation of base metal ores in tumbling mills
Weatherley, D. K. and Powell, M. S. (2017). Bivariate population balance equations for progressive weakening and fragmentation of base metal ores in tumbling mills. 9th Australasian Congress on Applied Mechanics, ACAM 2017, Sydney, NSW Australia, 27-29 November 2017 . Barton, ACT, Australia: Engineers Australia.
2016
Journal Article
Performance evaluation of the novel multi-shaft mill using DEM modelling
Bracey, R. J., Weerasekara, N. S. and Powell, M. S. (2016). Performance evaluation of the novel multi-shaft mill using DEM modelling. Minerals Engineering, 98, 251-260. doi: 10.1016/j.mineng.2016.09.007
2016
Journal Article
A phenomenological model of single particle breakage as a multi-stage process
Saeidi, Fatemeh, Tavares, Luis Marcelo, Yahyaei, Mohsen and Powell, Malcolm (2016). A phenomenological model of single particle breakage as a multi-stage process. Minerals Engineering, 98, 90-100. doi: 10.1016/j.mineng.2016.07.006
2016
Journal Article
Investigating internal classification within gravity induced stirred mills
Hasan, Maruf, Palaniandy, Sam, Hilden, Marko and Powell, Malcolm (2016). Investigating internal classification within gravity induced stirred mills. Minerals Engineering, 95, 5-13. doi: 10.1016/j.mineng.2016.05.019
2016
Journal Article
Developments in incremental rock breakage testing methodologies and modelling
Bonfils, Benjamin, Ballantyne, Grant R. and Powell, Malcolm S. (2016). Developments in incremental rock breakage testing methodologies and modelling. International Journal of Mineral Processing, 152, 16-25. doi: 10.1016/j.minpro.2016.04.010
2016
Conference Publication
A generic dynamic model incorporating a 4D appearance function for tumbling mills
Yu, Ping, Xie, Weiguo, Liu, Lian X., Weerasekara, Nirmal, Bonfils, Benjamin and Powell, Malcolm (2016). A generic dynamic model incorporating a 4D appearance function for tumbling mills. 28th International Mineral Processing Congress, IMPC 2016, Quebec City, Canada, 11-15 September 2016. Westmount, Canada: Canadian Institute of Mining, Metallurgy and Petroleum.
2016
Conference Publication
Understanding single particle breakage event to evaluate the effect of applied strain rate
Saeidi, Fatemeh, Yahyaei, Mohsen, Powell, Malcolm and Marcelo Tavares, Luis (2016). Understanding single particle breakage event to evaluate the effect of applied strain rate. XXVIII International Mineral Processing Congress Proceedings, Quebec City, Quebec, Canada, 11-15 September 2016. Canadian Institute Mining, Metallurgy and Petroleum.
2016
Conference Publication
Energy curve case study (AngloGold Ashanti)
Ballantyne, Grant R., Powell, M. S., Clarke, N., Di Trento, M., Kock, F. and Putland, B. (2016). Energy curve case study (AngloGold Ashanti). 2016 SME Annual Meeting & Exhibit (SME 2016), Phoenix, Arizona, 2016.
2016
Conference Publication
Extension of the comminution energy curves and application to stirred milling performance
Ballantyne, Grant, Powell, M. S. and Radziszewski, P. (2016). Extension of the comminution energy curves and application to stirred milling performance. Canadian Mineral Processing (CMP) Conference, Ottawa, Ontario, Canada, 19-21 January 2016. Ottawa, Ontario, Canada: Canadian Mineral Processing (CMP) Conference.
2016
Conference Publication
Using the comminution energy curves to assess equipment performance
Ballantyne, G. R. and Powell, M. S. (2016). Using the comminution energy curves to assess equipment performance. Comminution '16: 10th International Comminution Symposium, Capetown, South Africa, 11-14 April 2016. Capetown, South Africa: International Comminution Symposium.
2015
Journal Article
Relining efficiency and liner design for improved plant performance
Yahyaei, M, Powell, M.S, Toor, Paul, Tuxford, Andrew and Limpus, Andrew (2015). Relining efficiency and liner design for improved plant performance. Minerals Engineering, 83, 64-77. doi: 10.1016/j.mineng.2015.08.016
2015
Journal Article
Estimating energy in grinding using DEM modelling
Weerasekara, N. S., Liu, L. X. and Powell, M. S. (2015). Estimating energy in grinding using DEM modelling. Minerals Engineering, 85, 23-33. doi: 10.1016/j.mineng.2015.10.013
2015
Journal Article
The effects of electrical comminution on the mineral liberation and surface chemistry of a porphyry copper ore
Parker, Tamsyn, Shi, Feng N., Evans, Catherine L. and Powell, Malcolm (2015). The effects of electrical comminution on the mineral liberation and surface chemistry of a porphyry copper ore. Minerals Engineering, 82 4620, 101-106. doi: 10.1016/j.mineng.2015.03.019
2015
Journal Article
Characterisation of superficial breakage using multi-size pilot mills
Yahyaei, M., Weerasekara, N. S. and Powell, M. S. (2015). Characterisation of superficial breakage using multi-size pilot mills. Minerals Engineering, 81, 71-78. doi: 10.1016/j.mineng.2015.07.011
Funding
Past funding
Supervision
Availability
- Emeritus Professor Malcolm Powell is:
- Available for supervision
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Available projects
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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
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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
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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
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2016
Doctor Philosophy
Development of a correlation between mineralogy, rock strength measures, and breakage of Copper Porphyries
Principal Advisor
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2014
Master Philosophy
Grinding of Itabirite Iron Ore in Autogenous and Semi-Autogenous Mills.
Principal Advisor
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2014
Master Philosophy
Quantifying the Influence of Liner Wear on SAG Mill Performance
Principal Advisor
Other advisors: Dr Marko Hilden
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2023
Doctor Philosophy
Techno-Economic Multicomponent Analysis of Comminution Using Minerals Processing Simulators
Associate Advisor
Other advisors: Professor Mohsen Yahyaei
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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
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2020
Doctor Philosophy
The impact of classification efficiency on comminution performance and flotation recovery
Associate Advisor
Other advisors: Associate Professor Kym Runge
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2017
Master Philosophy
Development of a standard methodology for energy efficiency measurement in comminution processes
Associate Advisor
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2017
Doctor Philosophy
New Approach for Characterising a Breakage Event as a Multi-stage Process
Associate Advisor
Other advisors: Professor Mohsen Yahyaei
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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
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2016
Doctor Philosophy
Process Modelling of Gravity Induced Stirred Mills
Associate Advisor
Other advisors: Dr Marko Hilden
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2016
Master Philosophy
Application of the grindcurve methodology to AG/SAG mill control
Associate Advisor
Other advisors: Dr Marko Hilden
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2015
Master Philosophy
Developing an abrasion characterisation test for measuring superficial breakage in comminution
Associate Advisor
Other advisors: Professor Mohsen Yahyaei
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2014
Doctor Philosophy
A structured approach for integrating sustainable development principles into the decision-making processes at minerals processing operations
Associate Advisor
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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
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