
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
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.
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.
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.
2006
Conference Publication
The Unified Comminution Model - a Conceptually New Model
Powell, M.S. (2006). The Unified Comminution Model - a Conceptually New Model. Proceedings of the XXIII International Mineral Processing Congress, Istanbul, Turkey, 3 - 8 September, 2006.
2006
Conference Publication
Development of DEM validation tools with 3D X-ray particle tracking system
Govender, I., McBride, A. T. and Powell, M. S. (2006). Development of DEM validation tools with 3D X-ray particle tracking system. SEM06, St Louis, 4-7 June, 2006. USA: Society for Experimental Mechanics.
2006
Conference Publication
A structured approach to modelling SAG mill liner wear - monitoring wear
Powell, M. and Chandramohan, R. (2006). A structured approach to modelling SAG mill liner wear - monitoring wear. International Autogenous and Semiautogenous Grinding Technology 2006, Vancouver, Canada, 24-27 September 2006. Vancouver, Canada: CIM.
2006
Conference Publication
Industry taking the initiative in developing high calibre technical staff
Sweet, C.G., Sweet, J. A., Harris, M. C., Powell, M. S., Lambert, A. S., Charlesworth, P. and Knopjes, L. M. (2006). Industry taking the initiative in developing high calibre technical staff. The XXIII International Mineral Processing Congress, Istanbul, Turkey, 3-8 September 2006. Istanbul, Turkey: Promed Advertising Ltd.
2006
Book Chapter
The selection and design of mill liners
Powell, M. S., Smit, I., Radsizewski, P., Cleary, P., Rattray, B., Eriksson, K. and Schaeffer, L. (2006). The selection and design of mill liners. Advances in comminution. (pp. 331-376) edited by S . Komar Kawatra. Littleton, CO, United States: Society for Mining, Metallurgy & Exploration.
2006
Conference Publication
RoM Ball mills - a comparison with AG/SAG milling
Mainza, A and Powell, Malcolm (2006). RoM Ball mills - a comparison with AG/SAG milling. International autogenous and semi autogenous grinding technology 2006, Vancouver, Canada, 24 - 27 September 2006. Vancouver, Canada: CIM.
2006
Conference Publication
A Proposed Mechanistic slurry discharge model for AG/SAG mills
Condori, P. and Powell, M.S. (2006). A Proposed Mechanistic slurry discharge model for AG/SAG mills. International autogenous and semiautogenous grinding technology, Vancouver, Canada, 23-27 September, 2006. Vancouver, Canada: University of British Columbia, Dept of Mining and Mineral Process Engineering.
2006
Conference Publication
Enhancing platinum recovery with the three-product cyclone
Mainza, A. N., Powell, M.S. and Knopjes, B. (2006). Enhancing platinum recovery with the three-product cyclone. XXIII International Mineral Processing Congress, Istanbul, Turkey, 3-8 September 2006. Istanbul, Turkey: Promed Advertising Agency.
2005
Journal Article
A CFD simulation of a single phase hydrocyclone flow field
Dlamini, M. F., Powell, M. S. and Meyer, C. J. (2005). A CFD simulation of a single phase hydrocyclone flow field. Journal of the South African Institute of Mining and Metallurgy, 105 (10), 711-717.
2005
Conference Publication
Measurement of particle interaction properties for incorporation in the discrete element method simulation
Chandramohan, R. and Powell, M. S. (2005). Measurement of particle interaction properties for incorporation in the discrete element method simulation. JKMRC International Student Conference, Brisbane, Australia, 6-7 September 2004. Oxford, U.K.: Elsevier. doi: 10.1016/j.mineng.2005.06.004
2004
Journal Article
A three-dimensional analysis of media motion and grinding regions in mills
Powell, M. S. and McBride, A. T. (2004). A three-dimensional analysis of media motion and grinding regions in mills. Minerals engineering, 17 (11), 1099-1109. doi: 10.1016/j.mineng.2004.06.022
2004
Journal Article
Differential classification of dense material in a three-product cyclone
Mainza, A., Powell, M. S. and Knopjes, B. (2004). Differential classification of dense material in a three-product cyclone. Minerals engineering, 17 (5), 573-579. doi: 10.1016/j.mineng.2004.01.023
2004
Conference Publication
Using Particle Flow Code to investigate energy dissipation in a rotary grinding mill
Sarracino, R.S., McBride, A.T. and Powell, M.S. (2004). Using Particle Flow Code to investigate energy dissipation in a rotary grinding mill. Numerical Modeling in Micromechanics via Particle Methods, Kyoto, Japan, 28-29 October, 2004. Itasca.
2004
Journal Article
Contributions to the experimental validation of the discrete element method applied to tumbling mills
McBride, Andrew, Govender, Indresan, Powell, Malcolm and Cloete, Trevor (2004). Contributions to the experimental validation of the discrete element method applied to tumbling mills. Engineering Computations, 21 (2), 119-136. doi: 10.1108/02644400410519703
2004
Conference Publication
A comparison of different cyclones in addressing challenges in the classification of the dual density UG2 platinum ore
Mainza, A., Powell, M. S. and Knopjes, B. (2004). A comparison of different cyclones in addressing challenges in the classification of the dual density UG2 platinum ore. First International Platinum Conference ‘Platinum Adding Value’, Sun City, Rustenburg, South Africa, 3-7 October, 2004. Johannesburg, South Africa: The South African Institute of Mining and Metallurgy (SAIMM).
2003
Conference Publication
Use of the three-product cyclone in dual-density ore classification
Mainza, A. and Powell, M.S. (2003). Use of the three-product cyclone in dual-density ore classification. IMPC 2003, Cape Town, South Africa, 29 September- 3 October, 2003.
2003
Conference Publication
Application of DEM Outputs to Refining Applied SAG Mill Models
Powell, M. S., McBride, A. T. and Govender, I. (2003). Application of DEM Outputs to Refining Applied SAG Mill Models. IMPC 2003 Conference, Cape Town, South Africa, 28 September - 3 October , 2003. Marshalltown, South Africa: South African Institute of Mining and Metallurgy.
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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