Smart Industrial Equipment and Process Solutions

Transforming Industrial Equipment and Processes into Intelligent, Monitorable, and Analyzable Systems

Project Title

Intelligentization of Ball Mill Performance in an Iron Ore Processing Plant

Project Description​​​​​​​

This project focuses on developing an integrated approach based on multi-sensor monitoring and artificial intelligence to enhance the monitoring, control, and optimization of ball mill performance. In this approach, data from vibration, acoustic, and thermal analyses, along with strain-gauge measurements, are analyzed in an integrated manner to monitor and assess the structural health and performance of the mill without relying on periodic shutdowns.

The proposed solution incorporates a Digital Twin and a closed-loop intelligent control system to enable the prediction of key parameters, real-time response to feed variations, and automated process control. The ultimate goal is to move from operator experience-based monitoring and adjustments toward intelligent, data-driven control, with a focus on increasing production capacity, improving efficiency, and reducing energy consumption.

●  Online monitoring of the mill’s structural health and performance
●  Detection and prediction of shell cracks and damage
●  Integration of multi-sensor data and development of an intelligent monitoring system
●  Development of a Digital Twin of the mill
●  Prediction of key process parameters
●  Real-time autonomous control of mill performance
●  Optimization of production capacity and energy consumption
●  Implementation of a predictive maintenance approach
●  Reduction of forced downtime and maintenance costs

Project Outcomes

تبدیل تجهیزات و فرآیندهای صنعتی به سیستم های قابل پایش، تحلیل و تصمیم گیری هوشمند.

تبدیل تجهیزات و فرآیندهای صنعتی به سیستم های قابل پایش، تحلیل و تصمیم گیری هوشمند.

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