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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

205 works between 2001 and 2025

161 - 180 of 205 works

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.

Multiple-pass high pressure grinding rolls circuits

2008

Conference Publication

Extraction of DEM collision data for input to breakage models

Powell, M., Weerasekara, N., Khanal, M. and Favier, J. (2008). Extraction of DEM collision data for input to breakage models. Comminution 08, Falmouth, Cornwall, U.K., 17-20 June, 2008.

Extraction of DEM collision data for input to breakage models

2008

Conference Publication

Analysis of the breakage data of a series of devices

Bbosa, L. S., Mainza, A. N. and Powell, M. S. (2008). Analysis of the breakage data of a series of devices. XXIV International Mineral Processing Congress (XXIV IMPC), Beijing, China, 24-28 September, 2008. Beijing China: Science Press.

Analysis of the breakage data of a series of devices

2008

Conference Publication

Applying DEM outputs to the unified comminution model

Powell, M. S., Govender, I. and McBride, A. T. (2008). Applying DEM outputs to the unified comminution model. Discrete Element Methods (DEM) 07, Brisbane, Qld, Australia, 27-29 August, 2007. Oxford, England: Pergamon Press. doi: 10.1016/j.mineng.2008.06.010

Applying DEM outputs to the unified comminution model

2008

Conference Publication

The new energy logging from the discrete element method

Weerasekara, N. and Powell, M. (2008). The new energy logging from the discrete element method. Centre for Sustainable Resource Processing 2nd Annual Conference (CSRP'08), Brisbane, Australia, 18-19 November 2008. Kensington, WA, Australia: Centre for Sustainable Resource Processing.

The new energy logging from the discrete element method

2008

Conference Publication

Study of the efficiency of mineral department in the three product cyclone

Mainza, A. N. and Powell, M. S. (2008). Study of the efficiency of mineral department in the three product cyclone. XXIV International Mineral Processing Congress (XXIV IMPC), Beijing, China, 24-28 September, 2008. Beijing China: Science Press.

Study of the efficiency of mineral department in the three product cyclone

2008

Conference Publication

Applying DEM outputs to the unified comminution model

Powell, M., Weerasekara, N., Govender, I. and Khanal, M. (2008). Applying DEM outputs to the unified comminution model. Centre for Sustainable Resource Processing 2nd Annual Conference (CSRP'08), Brisbane, Australia, 18-19 November 2008. Kensington, WA, Australia: Centre for Sustainable Resource Processing.

Applying DEM outputs to the unified comminution model

2008

Conference Publication

A Mechanistic Approach to Modelling Slurry Transport in AG/SAG Mills: Transport through the Charge

Condori, P., Mainza, A., Govender, I. and Powell, M. S. (2008). A Mechanistic Approach to Modelling Slurry Transport in AG/SAG Mills: Transport through the Charge. XXIV International Mineral Processing Congress (XXIV IMPC), Beijing, China, 24-28 September 2008. Beijing, China: Science Press.

A Mechanistic Approach to Modelling Slurry Transport in AG/SAG Mills: Transport through the Charge

2007

Conference Publication

Positron emission particle tracking of charge particles in a scaled industrial tumbling mill

Govender, I, Powell, M S, Chandramohan, R, Parker, D J, Fan, X and Ingram, A (2007). Positron emission particle tracking of charge particles in a scaled industrial tumbling mill. Proceedings of Discrete Elements Methods 07, Brisbane, Aug 27-29, 2007. MEI Online.

Positron emission particle tracking of charge particles in a scaled industrial tumbling mill

2007

Conference Publication

Using DEM to inform experimental design

McBride, A.T. and Powell, M.S. (2007). Using DEM to inform experimental design. Discrete Element Methods, Brisbane, Australia, 27-29 August, 2007.

Using DEM to inform experimental design

2007

Conference Publication

A 3D X-ray Vision System for Studying Discrete Particulate Behaviour

Govender, I, and Powell, M. S. (2007). A 3D X-ray Vision System for Studying Discrete Particulate Behaviour. Discrete Element Methods 07, Brisbane, Australia, 27-29 August, 2007.

A 3D X-ray Vision System for Studying Discrete Particulate Behaviour

2006

Journal Article

Extended grinding curves are essential to the comparison of milling performance

Powell, Malcolm and Mainza, Aubrey (2006). Extended grinding curves are essential to the comparison of milling performance. Minerals Engineering, 19 (15), 1487-1494. doi: 10.1016/j.mineng.2006.08.004

Extended grinding curves are essential to the comparison of milling performance

2006

Conference Publication

Milling curves as a tool for characterising SAG mill performance

van der Westhuizen, A. P .P and Powell, M. S. (2006). Milling curves as a tool for characterising SAG mill performance. International autogenous and semiautogenous grinding technology, Vancouver, Canada, 24-27 September 2006. Vancouver, Canada: University of British Columbia, Dept of Mining and Mineral Process Engineering.

Milling curves as a tool for characterising SAG mill performance

2006

Conference Publication

Charge segregation and slurry transport in long SAG mills

Mwansa, S., Condori, P. and Powell, M. S. (2006). Charge segregation and slurry transport in long SAG mills. XXIII International Mineral Processing Congress (IMPC 2006), Istanbul, Turkey, 3-8 September 2006. Istanbul, Turkey: Promed Advertising.

Charge segregation and slurry transport in long SAG mills

2006

Journal Article

What is required from DEM simulation to model breakage in mills?

Powell, M S and McBride, A T (2006). What is required from DEM simulation to model breakage in mills?. Minerals engineering, 19 (10), 1013-1021. doi: 10.1016/j.mineng.2006.03.009

What is required from DEM simulation to model breakage in mills?

2006

Journal Article

Study of flow behaviour in a three-product cyclone using computational fluid dynamics

Mainza, A., Narasimha, M., Powell, M. S., Holtham, P. N. and Brennan, M. S. (2006). Study of flow behaviour in a three-product cyclone using computational fluid dynamics. Minerals Engineering, 19 (10), 1048-1058. doi: 10.1016/j.mineng.2006.03.014

Study of flow behaviour in a three-product cyclone using computational fluid dynamics

2006

Journal Article

Design for sampling - preliminary exploration

Morrison, R. and Powell, M. (2006). Design for sampling - preliminary exploration. Journal of The South African Institute of Mining And Metallurgy, 106 (10), 697-706.

Design for sampling - preliminary exploration

2006

Conference Publication

The value of rigorous surveys - the Los Bronces experience

Powell, M., Condori, P., Smit, I. and Valery, W. (2006). The value of rigorous surveys - the Los Bronces experience. International autogenous and semi autogenous grinding technology 2006, Vancouver, Canada, 24 - 27 Septmeber 2006. Canada: CIM.

The value of rigorous surveys - the Los Bronces experience

2006

Conference Publication

Applying discrete element modelling to different modes of breakage in AG and SAG mills

Morrison, R., Loveday, B., Powell, M. S., Djordjevic, N. and Cleary, P. (2006). Applying discrete element modelling to different modes of breakage in AG and SAG mills. International autogenous and semiautogenous grinding technology 2006, Vancouver, Canada, 23-27 September, 2006. Vancouver, Canada: University of British Columbia, Dept. of Mining Engineering.

Applying discrete element modelling to different modes of breakage in AG and SAG mills

2006

Conference Publication

A new look at breakage testing

Powell, Malcolm S. and Morrison, Rob D. (2006). A new look at breakage testing. 11th Euro. Symp. Comminution, Budapest, Hungary, 9-12 October, 2006. European Federation of Chemical Engineers.

A new look at breakage testing

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

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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