Proven Results

Grinding Circuit Optimization with Advanced Process Control

March 30, 2026

The Challenge

A gold mining operation was constrained by grinding circuit instability driven by a highly variable ore body. Operators relied on conventional regulatory controls, forcing a trade‑off between aggressive operation (leading to SAG mill overloads and trips) and conservative operation (reducing throughput). As the grinding circuit represented the site’s primary production bottleneck, instability directly impacted overall output and profitability.

The Solution

Spartan Controls deployed the SpartanPRO™ Grinding Circuit APC to coordinate crushers, SAG feed conveyors, SAG and ball mills, and primary cyclones as a single optimized system. The solution combined advanced mill sensing with adaptive control to automatically detect and respond to changes in ore characteristics.

By actively managing mill loading, shifting constraints, and early detection of overload conditions, the APC reduced operator intervention while improving overall stability and ease of operation. The solution has been in continuous operation since 2020.

The Value

The APC solution stabilized a critical production bottleneck and delivered sustained operational and financial gains:

8% increase in net throughput, valued at $30M per year
95%+ reduction in mill overload events and trips
75% reduction in mill load variability
80% reduction in operator actions

The grinding circuit APC has become the site’s standard operating mode, maintaining performance despite ongoing changes in feed material and operating conditions.

Grinding Circuit Optimization with Advanced Process Control

The Challenge

The Solution

The Value

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