Comminution Challenges

Today's mining operations face critical challenges that impact safety, efficiency, and profitability.

Sub-Optimal Productivity

Inefficient processes, unplanned downtime, and limited visibility into your operations reduce productivity and prevent mineral processing plants from reaching their full potential.

Additional Safety Risks

Aging equipment and inconsistent safety practices in crushing and grinding increase the risk of accidents, endangering workers and causing costly operational disruptions.

Low Throughput & Recovery

Inconsistent comminution performance and limited process visibility drive down throughput and recovery, eroding margins before the ore ever reaches flotation.

Emergency Plant Shutdowns

Unexpected plant shutdowns caused by large rock blockages in crushers, liner replacements in grinders, and other equipment failures lead to lost production time and increased operational costs.

Milling Process Inefficiencies

Variability in feed material and lack of real-time performance data on the grinder result in unstable milling conditions, increased energy use, and reduced throughput.

Plant Energy Inefficiencies

Excessive energy consumption caused by outdated equipment, poor process control, and unoptimized load distribution leads to higher operational costs and environmental impact.

Stone Three's Comminution Optimization Solution delivers up to

7 - 10% Throughput Improvement

Optimize my Crushing Circuit

Our Expert-Driven Solutions

Augmented Actions With AI-Driven Sensor Technology and Expert Domain Knowledge.

PSA/PSD
Oversize Detection
PSD/PSA
FOD
Screen Health
MagoSense
MagoLoad

Smart Sensors

We offer comprehensive sensor-based solutions, with AI-driven technology, tailored to different operational needs and scales.

Stone Three Truck PSD sensor delivering real-time particle size distribution measurement in mining haul trucks for comminution optimization and downstream process control.

Truck PSD

Provides accurate, real-time measurement of particle size distribution (PSD) in haul trucks, helping mines optimize downstream processes and improve overall efficiency.

  • Real-Time Particle Size Distribution
  • Sub-Optimal Blasting Detection
  • Primary Crusher Interlock
  • Enables Predictive & Feed-Forward Control
Stone Three Oversize Detection sensor identifying oversized rocks on mining conveyor in real time to prevent crusher blockages and protect equipment.

Oversize Detection

Identifies oversized rocks in real time, helping mines reduce equipment damage and maintain consistent material flow.

  • Oversize Material Detection
  • Prevent Crusher Blockages
  • Protect & Maintain Equipment
  • Improve Safety - Less Manual Intervention
Stone Three Conveyor PSD sensor delivering real-time crushed ore particle size monitoring on a mining conveyor belt, enabling automatic crusher gap adjustment and improved downstream flotation recovery.

Conveyor PSD

Provides continuous, real-time monitoring of material size on conveyors, enabling better control of downstream processes and overall plant efficiency.

  • Sub-Optimal Crushing Detection
  • Sub-Optimal Milling Detection
  • Auto-Adjust Feed & Crusher Gap
  • Real-Time Oversize Detection
Stone Three Foreign Object Detection sensor monitoring mining conveyor belt in real time to prevent catastrophic equipment damage and reduce unplanned downtime.

Conveyor FOD

Enables real-time detection of foreign objects on conveyor belts, helping mines prevent equipment damage, reduce downtime, and enhance operational safety.

  • Prevent Catastrophic Equipment Damage
  • Protect High Value Assets
  • Enhance Operational Reliability
  • Provide Actionable Intelligence
Conveyor Volume Sensor

Conveyor Volume

Delivers accurate, real-time measurement of material volume on conveyor belts, enabling better control of throughput, improved plant efficiency, and informed decision-making.

  • Real-Time Material Flow Visibility
  • Improve Process Stability & Efficiency
  • Enhance Forecast & Throughput Tracking
  • Supports Feed-Forward Control
Stone Three Screen Health Monitoring sensor detecting vibrating screen panel failures in real time to protect grinding circuit efficiency and prevent oversize bypass.

Screen Health Monitoring

Enables real-time diagnostics of screen integrity by detecting panel dislodgment and oversize bypass, ensuring stable operation of downstream circuits.

  • Screen Panel Failure Detection
  • Oversize Detection Alert
  • Protects Grinding Efficiency
  • Mitigate Equipment Damage
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Advanced Process Control

Automated, adaptive, and performance-driven solution that uses predictive models and sensor data to automatically adjust key variables in crushing and milling, maximizing throughput, improving efficiency, stabilizing the circuit, and enhancing downstream recovery.

Crushing APC

A real-time optimization system that monitors and controls key parameters such as crusher feed rate, closed-side setting (CSS), and power draw to maximize throughput, minimize liner wear, and maintain consistent product size. APC ensures stable crusher operation and improved efficiency across the comminution circuit.

Phase 1: Stabilization

Stabilization is the first step in implementing APC in crushing operations. This phase focuses on establishing consistent operations and reducing variability.

  • Ore Feed Stabilization
  • Ore Feed PSD Stabilization
  • Circuit Load Control

Phase 2: Optimization

Optimization is the second step in implementing APC in crushing operations. This phase focuses on ensuring sustainable results.

  • Product PSD Control

Grinding APC

A real-time control system that uses predictive models and live sensor data to optimize mill operation by automatically adjusting variables like feed rate, mill speed, and water addition. APC enhances throughput, reduces energy consumption, improves particle size distribution, and stabilizes the grinding circuit for consistent and on target mineral liberation to enhance flotation recovery.

Phase 1: Stabilization

Stabilization is the first step in implementing APC in grinding operations. This phase focuses on establishing consistent operations and reducing variability.

  • Mill Feed Stabilization
  • Power/Load Control
  • Cyclone Split Control

Phase 2: Optimization

Optimization is the second step in implementing APC in grinding operations. This phase focuses on ensuring sustainable results.

  • Mill Feed Blend Control
  • Power/Load Optimization
  • % Passing Control

SmartROC™

Stone Three's SmartROC™ combines expert process knowledge with AI-powered machine learning to deliver remote visibility and actionable insights across your operation, reducing downtime and driving consistent plant performance.

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