
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
2013
Conference Publication
The role of classification in an evolving comminution circuit
Mainza, A., Evertsson, M., Benzer, H., Tavarese, M., Powell, M. S., Rule, C., Plint, N., Lombard, M. and Knopjes, B. (2013). The role of classification in an evolving comminution circuit. ESCC2013: 13th European Symposium on Comminution and Classification, Braunschweig, Germany, 9-12 September, 2013. Göttingen, Germany: Sierke Verlag.
2013
Conference Publication
Pushing the boundaries of comminution with mechanistic modelling and multi-component process simulation
Powell, M. S. (2013). Pushing the boundaries of comminution with mechanistic modelling and multi-component process simulation. ESCC2013: 13th European Symposium on Comminution and Classification, Braunschweig, Germany, 9-12 September, 2013. Göttingen, Germany: Sierke Verlag.
2013
Conference Publication
Performance characterisation of AG/SAG mill pulp lifters using CFD techniques
Weerasekara, N. S. and Powell, M. S. (2013). Performance characterisation of AG/SAG mill pulp lifters using CFD techniques. Computational Modelling '13, Falmouth, Cornwall, U.K., 18-19 June, 2013. Falmouth, Cornwall, U.K.: Minerals Engineering International.
2013
Conference Publication
Utilising orebody knowledge to improve comminution circuit design and energy utilisation
Powell, M. S. (2013). Utilising orebody knowledge to improve comminution circuit design and energy utilisation. GeoMet 2013: The Second AusIMM International Geometallurgy Conference, Brisbane, QLD, Australia, 30 September-2 October, 2013. Carlton, VIC, Australia: The Australasian Institute of Mining and Metallurgy (AusIMM).
2013
Conference Publication
Size specific energy (SSE): energy required to generate minus 75 micron material
Ballantyne, G. R., Yang, A. L., Powell, M. S. and Peukert, W. (2013). Size specific energy (SSE): energy required to generate minus 75 micron material. ESCC2013: 13th European Symposium on Comminution and Classification, Braunschweig, Germany, 9-12 September, 2013. Göttingen, Germany: Sierke Verlag.
2013
Conference Publication
Facing the challenges of new low-grade orebodies with new economic circuit designs
Powell, Malcolm (2013). Facing the challenges of new low-grade orebodies with new economic circuit designs. II International Meeting on Metallurgy Peru 2013: Plants and Processes, Lima, Peru, 1-3 November, 2013.
2013
Conference Publication
The future developments in circuit simulation capability at the JKMRC
Hilden, M., Stange, W., Powell, M. S. and Andrusiewicz, M. (2013). The future developments in circuit simulation capability at the JKMRC. ESCC2013: 13th European Symposium on Comminution and Classification, Braunschweig, Germany, 9-12 September, 2013. Göttingen, Germany: Sierke Verlag.
2013
Conference Publication
Characterisation of abrasion breakage using multi size pilot mills
Yahyaei, Mohsen, Weerasekara, Nirmal and Powell, Malcolm (2013). Characterisation of abrasion breakage using multi size pilot mills. 13th European Symposium on Comminution and Classification, Braunschweig, Germany, 9-12 September 2013. Gottingen, Germany: Sierke Verlag.
2013
Conference Publication
Developments in incremental rock breakage testing methodologies and modelling
Bonfils, B. and Powell, M. S. (2013). Developments in incremental rock breakage testing methodologies and modelling. ESCC2013: 13th European Symposium on Comminution and Classification, Braunschweig, Germany, 9-12 September, 2013. Göttingen, Germany: Sierke Verlag.
2013
Journal Article
The contribution of DEM to the science of comminution
Weerasekara, N. S., Powell, M. S., Cleary, P. W., Tavares, L. M., Evertsson, M., Morrison, R. D., Quist, J. and Carvalho, R. M. (2013). The contribution of DEM to the science of comminution. Powder Technology, 248, 3-24. doi: 10.1016/j.powtec.2013.05.032
2013
Conference Publication
VertiMill® - development of circuit survey and performance evaluation protocols
Palaniandy, S., Powell, M., Hilden, M., Kermanshahi, K., Allen, J. and Mwansa, S. (2013). VertiMill® - development of circuit survey and performance evaluation protocols. Metallurgical Plant Design and Operating Strategies (MetPlant 2013), Perth, WA, Australia, 15-17 July 2013. Carlton, VIC, Australia: Australasian Institute of Mining and Metallurgy (AusIMM).
2012
Journal Article
A practical and rigorous approach for the integration of sustainability principles into the decision-making processes at minerals processing operations
Tuazon, D., Corder, G., Powell, M. and Ziemski, M. (2012). A practical and rigorous approach for the integration of sustainability principles into the decision-making processes at minerals processing operations. Minerals Engineering, 29, 65-71. doi: 10.1016/j.mineng.2011.10.017
2012
Conference Publication
Updated Julius Kruttschnitt semi-autogenous grinding mill model
Kojovic, T., Hilden, M. M., Powell, M. S. and Bailey, C. (2012). Updated Julius Kruttschnitt semi-autogenous grinding mill model. 11th AusIMM Mill Operators' Conference 2012, Hobart, Victoria, 29-31 October 2012. Carlton, Victoria: AusIMM: Australasian Institute of Mining and Metallurgy.
2012
Journal Article
Designing liners for performance not life
Toor, Paul, Franke, Jochen, Powell, Malcolm, Bird, Matthew and Waters, Thomas (2012). Designing liners for performance not life. Minerals Engineering, 43-44, 22-28. doi: 10.1016/j.mineng.2012.07.004
2012
Conference Publication
Early rejection of gangue - How much energy will it cost to save energy?
Ballantyne, Grant, Hilden, Marko and Powell, Malcolm (2012). Early rejection of gangue - How much energy will it cost to save energy?. Comminution '12: 8th International Comminution Symposium, Cape Town, South Africa, 17-20 April 2012.
2012
Conference Publication
Simulation of flexible circuits
Foggiatto, B., Hilden, M. M., Powell, M. S., Kay, P. D. and Andrusiewicz, M. (2012). Simulation of flexible circuits. 11th AusIMM Mill Operators' Conference 2012, Hobart, Tasmania, 29-31 October 2012. Carlton, Victoria: AusIMM: Australasian Institute of Mining and Metallurgy.
2012
Journal Article
Multi-component AG/SAG mill model
Bueno, Marcos, Kojovic, Toni, Powell, Malcolm and Shi, Feng N. (2012). Multi-component AG/SAG mill model. Minerals Engineering, In Press, Corrected Proof, 12-21. doi: 10.1016/j.mineng.2012.06.011
2012
Conference Publication
Proportion of energy attributable to comminution
Ballantyne, G. R., Powell, M. S. and Tiang, M. (2012). Proportion of energy attributable to comminution. 11th AusIMM Mill Operators' Conference 2012, Hobart, Tasmania, 29-31 October 2012. Carlton, Australia: AusIMM: Australasian Institute of Mining and Metallurgy.
2012
Conference Publication
Optimisation opputunities for high pressure grinding rolls circuits
Powell, M. S., Hilden, M. M., Evertsson, C. M., Asbjornsson, G., Benzer, A. H., Mainza, A. N., Tavares, L. M., Davis, B., Plint, N. and Rule, C. (2012). Optimisation opputunities for high pressure grinding rolls circuits. 11th AusIMM Mill Operators' Conference 2012, Hobart,Tasmania, 29-31 October 2012. Carlton, Victoria: AusIMM: Australasian Institute of Mining and Metallurgy.
2012
Conference Publication
Comparing power draw predictions in experimental scale tumbling mills using PEPT and DEM
Bbosa, L., Govender, I., Mainza, A., Powell, M. and Plint, N. (2012). Comparing power draw predictions in experimental scale tumbling mills using PEPT and DEM. XXVI International Mineral Processing Congress - IMPC 2012, New Delhi, India, 24-28 September 2012. New Delhi, India: Technowrites.
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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