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Emeritus Professor Malcolm Powell
Emeritus Professor

Malcolm Powell

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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

41 - 60 of 204 works

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

The development of the wide-range 4D appearance function for breakage characterisation in grinding mills

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

Assessment of hydrocyclone operation in gravity induced stirred mill circuit

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

Analytical solution for the dynamic model of tumbling mills

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

HPGR simulation from piston-die tests with an itabirite ore

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.

The Impact of Classification Efficiency on Comminution and Flotation Circuit Performance

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

Investigating the effect of applied strain rate in a single breakage event

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.

Bivariate population balance equations for progressive weakening and fragmentation of base metal ores in tumbling mills

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

Performance evaluation of the novel multi-shaft mill using DEM modelling

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

A phenomenological model of single particle breakage as a multi-stage process

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

Investigating internal classification within gravity induced stirred mills

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

Developments in incremental rock breakage testing methodologies and modelling

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.

A generic dynamic model incorporating a 4D appearance function for tumbling mills

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.

Understanding single particle breakage event to evaluate the effect of applied strain rate

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.

Energy curve case study (AngloGold Ashanti)

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.

Extension of the comminution energy curves and application to stirred milling performance

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.

Using the comminution energy curves to assess equipment performance

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

Relining efficiency and liner design for improved plant performance

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

Estimating energy in grinding using DEM modelling

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

The effects of electrical comminution on the mineral liberation and surface chemistry of a porphyry copper ore

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

Characterisation of superficial breakage using multi-size pilot 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

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

communications@uq.edu.au