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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

61 - 80 of 204 works

2015

Other Outputs

Putting the microscope over power consumption

Ballantyne, Grant and M. S. Powell (2015, 03 26). Putting the microscope over power consumption Queensland Industry Advocate

Putting the microscope over power consumption

2015

Journal Article

VertiMill® - preparing the feed within floatable regime at lower specific energy

Palaniandy, Samayamutthirian, Powell, Malcolm, Hilden, Marko, Allen, Jonathan, Kermanshahi, Kamran, Oats, Bill and Lollback, Mark (2015). VertiMill® - preparing the feed within floatable regime at lower specific energy. Minerals Engineering, 73, 44-52. doi: 10.1016/j.mineng.2014.11.014

VertiMill® - preparing the feed within floatable regime at lower specific energy

2015

Journal Article

Size specific energy (SSE) - energy required to generate minus 75 micron material

Ballantyne, Grant R., Peukert, Wolfgang and Powell, Malcolm S. (2015). Size specific energy (SSE) - energy required to generate minus 75 micron material. International Journal of Mineral Processing, 136, 2-6. doi: 10.1016/j.minpro.2014.09.010

Size specific energy (SSE) - energy required to generate minus 75 micron material

2015

Journal Article

Introducing the concept of mechanical texture in comminution: The case of concrete recycling

Bourgeois, Florent S., Lippiatt, Nicholas R. and Powell, Malcolm S. (2015). Introducing the concept of mechanical texture in comminution: The case of concrete recycling. International Journal of Mineral Processing, 136, 7-14. doi: 10.1016/j.minpro.2014.09.012

Introducing the concept of mechanical texture in comminution: The case of concrete recycling

2015

Conference Publication

The Cadia Hpgr-Sag Circuit – from design to operation – the commissioning challenge

Engelhardt, Dieter, Seppelt, Joe, Waters, Tom, Apfelt, Andy, Lane, Greg, Yahyaei, Mohsen and Powell, Malcolm (2015). The Cadia Hpgr-Sag Circuit – from design to operation – the commissioning challenge. The 6th International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, BC, Canada, 20-24 September 2015. Vancouver, BC, Canada: Canadian Institute of Mining and Metallurgy (CIM).

The Cadia Hpgr-Sag Circuit – from design to operation – the commissioning challenge

2015

Conference Publication

Development of the comminution 'energy curve'

Ballantyne, G. R. and Powell, M. S. (2015). Development of the comminution 'energy curve'. 6th International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, Canada, 20 - 24 September, 2015. Vancouver, Canada: SAG Conference.

Development of the comminution 'energy curve'

2015

Conference Publication

Modelling single particle breakage as a multi-stage process

Saeidi, Fatemeh, Marcelo Tavares, Luis, Yahyaei, Mohsen and Powell, Malcolm (2015). Modelling single particle breakage as a multi-stage process. 14th European Symposium on Comminution and Classification, Gothenburg, Sweden, 7-10 September 2015. Gothenberg, Sweden: Chalmers University of Technology.

Modelling single particle breakage as a multi-stage process

2015

Conference Publication

Double Impact Breakage: Comparison and Extension of Size Specific Energy Methodology

Reja, Y., Ballantyne, G. R., Bonfils, B. and Powell, M. S. (2015). Double Impact Breakage: Comparison and Extension of Size Specific Energy Methodology. European Symposium of Comminution and Classification (ESCC), Gothenburg, Sweden, 2015.

Double Impact Breakage: Comparison and Extension of Size Specific Energy Methodology

2015

Conference Publication

Full pre-crush to sag mills – the case for changing this practice

Powell, Malcolm S., Mainza, Aubrey N., Hilden, Marko H. and Yahyaei, Mohsen (2015). Full pre-crush to sag mills – the case for changing this practice. The 6th International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, BC, Canada, 20-24 September 2015. Vancouver, BC, Canada: Canadian Institute of Mining and Metallurgy (CIM).

Full pre-crush to sag mills – the case for changing this practice

2015

Conference Publication

Application of research principles to identify process improvement at Sunrise Dam Gold Mine

G. R. Ballantyne, N. Clarke, P. Elms, A. Anyimadu and M. S. Powell (2015). Application of research principles to identify process improvement at Sunrise Dam Gold Mine. MetPlant 2015: Plant Design & Operating Strategies - World's Best Practice, Perth, Australia, 7-8 September, 2015. Melbourne, Australia: The Australasian Institute of Mining and Metallurgy.

Application of research principles to identify process improvement at Sunrise Dam Gold Mine

2015

Conference Publication

A study of the effect of particle size on surface breakage in a pilot mill

Yahyaei, M., Weerasekara, N. and Powell, M. (2015). A study of the effect of particle size on surface breakage in a pilot mill. 14th European Symposium on Comminution and Classification, Gothenburg, Sweden, 7-10 September 2015. Gothenberg, Sweden: Chalmers University of Technology.

A study of the effect of particle size on surface breakage in a pilot mill

2015

Conference Publication

Improving SAG mill performance and controllability by leveraging the modified size distributions from Grade Engineering®

Ballantyne, Grant R., Foggiatto, B., Carrasco, C., Hilden, M. and Powell, M. S. (2015). Improving SAG mill performance and controllability by leveraging the modified size distributions from Grade Engineering®. 6th International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, BC, Canada, 20-24 September 2015. Vancouver, BC, Canada: Canadian Institute of Mining and Metallurgy (CIM).

Improving SAG mill performance and controllability by leveraging the modified size distributions from Grade Engineering®

2015

Conference Publication

Simple energy measures for assessing total circuit efficiency

Ballantyne, Grant, Powell, M. S., Bonfils, B. and Yahyaei, M. (2015). Simple energy measures for assessing total circuit efficiency. 6th International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, Canada, 20 - 24 September 2015.

Simple energy measures for assessing total circuit efficiency

2015

Conference Publication

Understanding the effects of liner wear on SAG mill performance

Toor, Paul, Powell, Malcolm, Hilden, Marko and Weerasekara, Nirmal (2015). Understanding the effects of liner wear on SAG mill performance. MetPlant 2015, Perth, Australia, 7-8 September 2015. The Australasian Institute of Mining and Metallurgy.

Understanding the effects of liner wear on SAG mill performance

2015

Conference Publication

Improving liner design for efficiency

Yahyaei, Mohsen, Limpus, Andrew, Russell, John, Toor, Paul and Powell, Malcolm (2015). Improving liner design for efficiency. The 6th International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, BC, Canada, 20-24 September 2015. Vancouver, BC, Canada: Canadian Institute of Mining and Metallurgy (CIM).

Improving liner design for efficiency

2015

Conference Publication

Using comminution energy intensity curves to assess efficiency of gold processing circuits

Ballantyne, G. R., Mainza, A. and Powell, M. S. (2015). Using comminution energy intensity curves to assess efficiency of gold processing circuits. World Gold 2015, Johannesburg, South Africa, 29 September - 1 October, 2015. Johannesburg South Africa: Southern African Institute of Mining and Metallurgy.

Using comminution energy intensity curves to assess efficiency of gold processing circuits

2015

Conference Publication

Measuring shear abrasion breakage of rocks using a novel characterisation experiment

Masuret, C., Yahyaei, M., Weerasekara, N. and Powell, M. (2015). Measuring shear abrasion breakage of rocks using a novel characterisation experiment. 14th European Symposium on Comminution and Classification, Gothenburg, Sweden, 7-10 September 2015. Gothenberg, Sweden: Chalmers University of Technology.

Measuring shear abrasion breakage of rocks using a novel characterisation experiment

2015

Conference Publication

Simulations of expansion scenarios of a standard SABC circuit

Bonfils, Benjamin, Powell, Malcolm and Tello, Sebastian (2015). Simulations of expansion scenarios of a standard SABC circuit. International Conference on Semi-Autogenous and High Pressure Grinding Technology, Vancouver, Canada, 20-24 September 2015.

Simulations of expansion scenarios of a standard SABC circuit

2014

Journal Article

Development of an effective and practical Process Alteration Index (PAI) for predicting metallurgical responses of Cu porphyries

Yildirim, Baris G., Bradshaw, Dee, Powell, Malcolm, Evans, Cathy and Clark, Alice (2014). Development of an effective and practical Process Alteration Index (PAI) for predicting metallurgical responses of Cu porphyries. Minerals Engineering, 69, 91-96. doi: 10.1016/j.mineng.2014.07.009

Development of an effective and practical Process Alteration Index (PAI) for predicting metallurgical responses of Cu porphyries

2014

Journal Article

Benchmarking comminution energy consumption for the processing of copper and gold ores

Ballantyne, G. R. and Powell, M. S. (2014). Benchmarking comminution energy consumption for the processing of copper and gold ores. Minerals Engineering, 65, 109-114. doi: 10.1016/j.mineng.2014.05.017

Benchmarking comminution energy consumption for the processing of copper and gold ores

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