
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
2011
Conference Publication
Cadia expansion - from Open Pit to Block Cave and beyond
Engelhardt, Dieter, Robertson, Jason, Lane, Greg, Powell, Malcolm and Griffin, Paul (2011). Cadia expansion - from Open Pit to Block Cave and beyond. International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Rolls Technology 2011, Vancouver BC, Canada, 25-28 September, 2011. Canada: Canadian Institute of Mining and Metallurgy.
2011
Conference Publication
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. (2011). A practical and rigorous approach for the integration of sustainability principles into the decision-making processes at minerals processing operations. Sustainability through Resource Conservation and Recycling 2011, Falmouth, Cornwall, United Kingdom, 10-12 May 2011.
2011
Conference Publication
Transforming the effectiveness of the HPGR circuit at Anglo Platinum Mogalakwena
Powell, Malcolm, Benzer, Hakan, Mainza, Aubrey, Evertsson, Magnus, Tavares, Marcelo, van Drunick, Wayne, Potgieter, Mani, Davis, Barry, Plint, Neville and Rule, Chris (2011). Transforming the effectiveness of the HPGR circuit at Anglo Platinum Mogalakwena. International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Rolls Technology 2011, Vancouver BC, Canada, 25-28 September, 2011. Canada: Canadian Institute of Mining and Metallurgy.
2010
Journal Article
A new predictive model of lifter bar wear in mills
Rezaeizadeh, M., Fooladi, M., Powell, M. S., Mansouri, S. H. and Weerasekara, N. S. (2010). A new predictive model of lifter bar wear in mills. Minerals Engineering, 23 (15), 1174-1181. doi: 10.1016/j.mineng.2010.07.016
2010
Journal Article
Experimental observations of lifter parameters and mill operation on power draw and liner impact loading
Rezaeizadeh, M., Fooladi, M., Powell, M. S. and Mansouri, S. H. (2010). Experimental observations of lifter parameters and mill operation on power draw and liner impact loading. Minerals Engineering, 23 (15), 1182-1191. doi: 10.1016/j.mineng.2010.07.017
2010
Journal Article
Energy representation for the Unified Comminution Model
Khanal, Manoj and Powell, Malcolm (2010). Energy representation for the Unified Comminution Model. Particulate Science and Technology: an international journal, 28 (6), 529-538. doi: 10.1080/02726350903579348
2010
Journal Article
An experimental investigation of the effects of operating parameters on the wear of lifters in tumbling mills
Rezaeizadeh, M., Fooladi, M., Powell, M. S. and Weerasekara, N. S. (2010). An experimental investigation of the effects of operating parameters on the wear of lifters in tumbling mills. Minerals Engineering, 23 (7), 558-562. doi: 10.1016/j.mineng.2009.12.010
2010
Conference Publication
Using positron emission particle tracking (PEPT) to investigate industrial systems
Govender, I., Morrison, A. J., Mainza, A., van der Westuizen, A., Franzidis, J.-P. and Powell, Malcolm (2010). Using positron emission particle tracking (PEPT) to investigate industrial systems. International Mineral Processing Congress 2010, Brisbane, QLD, Australia, 6-10 September 2010. Carlton, VIC, Australia: Australasian Institute of Mining and Metallurgy.
2010
Conference Publication
Human control in mineral processing plants: An operator centered investigation
Li, Xilin, Horberry, Tim and Powell, Malcolm (2010). Human control in mineral processing plants: An operator centered investigation. Human Factors and Ergnonomics Society 54th ANNUAL MEETING - 2010, San Francisco, CA, U.S.A, 27 September - 1 October 2010. San Francisco, U.S.A.: Human Factors and Ergonomics Society. doi: 10.1518/107118110X12829369201151
2010
Conference Publication
Modeling breakage environment in tumbling mills using DEM and analyzing the outputs
Weerasekara, N. S., Powell, M. S., Cole, S. and Favier, J. (2010). Modeling breakage environment in tumbling mills using DEM and analyzing the outputs. DEM5: The Fifth International Conference on Discrete Element Methods, University of London, 25-26 August, 2010. University of London, London, United Kingdom: Queen Mary.
2010
Conference Publication
Investigation on multicomponent semi-autogenous grinding
Bueno, Marcos, Shi, Feng N., Kojovic, Toni and Powell, Malcolm (2010). Investigation on multicomponent semi-autogenous grinding. International Mineral Processing Congress 2010, Brisbane, Qld, Australia, 6-10 September, 2010. Carlton, VIC, Australia: Australasian Institute of Mining and Metallurgy.
2010
Conference Publication
PEPT Cape Town: A new positron emission particle tracking facility at iThemba LABS
Buffler, A., Govender, I., Cilliers, J. J., Parker, D. J., Franzidis, J.-P., Mainza, A., Newman, R.T., Powell, M. and Van Der Westhuizen, A. (2010). PEPT Cape Town: A new positron emission particle tracking facility at iThemba LABS. IAEA International Topical Meeting on Nuclear Research Applications and Utilization of Accelerators, Vienna, 4-8 May 2009. Vienna: International Atomic Energy Agency (IAEA.
2010
Conference Publication
The influence of particle shape in rock fracture
Chandramohan, Rajiv, Holtham, Peter N. and Powell, Malcolm (2010). The influence of particle shape in rock fracture. International Mineral Processing Congress 2010, Brisbane, Qld, Australia, 6-10 September, 2010. Carlton, VIC, Australia: Australasian Institute of Mining and Metallurgy.
2010
Conference Publication
Building the unified comminution model
Powell, Malcolm and Weerasekara, Nirmal (2010). Building the unified comminution model. International Mineral Processing Congress 2010, Brisbane, Qld, Australia, 6-10 September, 2010. Carlton, VIC, Australia: Australasian Institute of Mining and Metallurgy.
2009
Journal Article
Foreword
Powell, M. S. (2009). Foreword. Minerals Engineering, 22 (7-8), 575-575. doi: 10.1016/j.mineng.2009.04.006
2009
Conference Publication
The water efficient plant of the future: Towards a holistic process chain approach.
de Kretser, R. G., Powell, M., Scales, P. J. and Lim, J. (2009). The water efficient plant of the future: Towards a holistic process chain approach.. WIM 2009, Perth, WA, 15-17 September, 2009. Carlton, VIC: AusIMM.
2008
Journal Article
Quantifying the influence of classification with the 3 product cyclone on liberation and recovery of PGMs in UG2 ore
Becker, M., Mainza, A. N., Powell, M. S., Bradshaw, D. J. and Knopjes, B. (2008). Quantifying the influence of classification with the 3 product cyclone on liberation and recovery of PGMs in UG2 ore. Minerals Engineering, 21 (7), 549-558. doi: 10.1016/j.mineng.2007.11.001
2008
Conference Publication
Challenges in applying the unified comminution model
Powell, M., Govender, I. and McBride, A. T. (2008). Challenges in applying the unified comminution model. XXIV International Mineral Processing Congress (XXIV IMPC), Beijing, China, 24-28 September, 2008. Beijing, China: Science Press.
2008
Conference Publication
Applying computationally intensive techniques to modelling of comminution devices
Cleary, P. W., Powell, M. S. and Morrison, R. D. (2008). Applying computationally intensive techniques to modelling of comminution devices. XXIV International Mineral Processing Congress (XXIV IMPC), Beijing, China, 24-28 September 2008. Beijing, China: Science Press.
2008
Conference Publication
Multiple-pass high pressure grinding rolls circuits
Hilden, M. and Powell, M. (2008). Multiple-pass high pressure grinding rolls circuits. Centre for Sustainable Resource Processing 2nd Annual Conference (CSRP'08), Brisbane, Australia, 18-19 November 2008. Kensington, WA, Australia: Centre for Sustainable Resource Processing.
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
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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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