Abstract: Apparatus features a signal processor or signal processing module configured to: receive signaling containing information about an acoustic noise profile that is directly measured and generated by a slurry hitting a probe configured in a part of a cyclone; and determine corresponding signaling containing information about the status of the part of the cyclone, based upon the signaling received. The signal processor or signal processing module is configured to provide the corresponding signaling, including where the corresponding signaling provided contains information about whether the part of the cyclone is damaged or worn. The part of the cyclone is an apex of the cyclone, and the corresponding signaling contains information about the status of the apex of the cyclone.

Abstract: A mineral processing system featuring a controller having a signal processor or processing module configured to: receive signaling containing information about a relationship between multiple particle size measurements of different measured particles having different measured particle sizes flowing in a hydrocyclone classifier overflow stream sensed by at least one particle size measurement device arranged on a hydrocyclone classifier overflow pipe of at least one hydrocyclone in a hydrocyclone battery, and about a floatable fraction that defines a particle size range of different floatable particle sizes of different floatable particles that can be recovered by the at least one hydrocyclone in the hydrocyclone battery; and determine corresponding signaling containing information to control a ground product size of ore having ground particles provided to the at least one hydrocyclone in the hydrocyclone battery, based upon the signaling received.

Abstract: A mineral extraction system features at least one hydrocyclone, each having input piping, underflow piping, a cyclone portion and overflow piping; a particle size measurement device arranged on some part of the at least one hydrocyclone and configured to sense particles flowing in a process medium, and providing signaling containing information about the size of the particles in the process medium; and a controller having a signal processor configured to receive the signaling, and determine control signaling to control some part of the mineral extraction system, based upon the signaling received.

Abstract: A mineral processing system featuring a controller having a signal processor or processing module configured to: receive signaling containing information about a relationship between multiple particle size measurements of different measured particles having different measured particle sizes flowing in a hydrocyclone classifier overflow stream sensed by at least one particle size measurement device arranged on a hydrocyclone classifier overflow pipe of at least one hydrocyclone in a hydrocyclone battery, and about a floatable fraction that defines a particle size range of different floatable particle sizes of different floatable particles that can be recovered by the at least one hydrocyclone in the hydrocyclone battery; and determine corresponding signaling containing information to control a ground product size of ore having ground particles provided to the at least one hydrocyclone in the hydrocyclone battery, based upon the signaling received.

Abstract: Apparatus features a signal processor or signal processing module configured to: receive signaling containing information about a central air-core of an overflow pipe of a hydrocyclone where fluid flow is concentrated in an outer annular region of the overflow pipe that is against an inner wall of the overflow pipe during a normal operation of the hydrocyclone; and determine corresponding signaling containing information about a collapse of the central air-core of the overflow pipe of the hydrocyclone during an abnormal operation of the hydrocyclone, based upon the signaling received. The signaling contains information about a fluid flow rate of the fluid flow by detecting a change in the magnitude of a force and/or a moment on the probe.

Abstract: A mineral extraction system features at least one hydrocyclone, each having input piping, underflow piping, a cyclone portion and overflow piping; a particle size measurement device arranged on some part of the at least one hydrocyclone and configured to sense particles flowing in a process medium, and providing signaling containing information about the size of the particles in the process medium; and a controller having a signal processor configured to receive the signaling, and determine control signaling to control some part of the mineral extraction system, based upon the signaling received.

Abstract: A signal processor is provided comprising one or more signal processor modules configured to: compare signaling containing information about historical data related to the performance of a pump; and provide corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump. The one or more signal processor modules may be configured to compare over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump, including tracking a ratio of hydraulic to electric power.

Abstract: Apparatus is provided including a signal processor or signal processing module configured at least to: respond to signaling containing information about particle sizes of solids forming part of a slurry stream being fed with a common feed flow into a battery of cyclones; and determine which combinations of cyclones in the battery produce overflow that has undesirable particle size characteristics using a statistical algorithm or technique, based upon the signaling received. The signal processor or signal processing module provides corresponding signaling containing about which combinations of cyclones in the battery produce overflow that has undesirable particle size characteristics, including control signaling to control the operation of the battery, including information about certain combinations of cyclones to avoid, or preferentially to use, to minimize the total amount of coarse material having the undesirable particle size characteristics produced by the battery.

Abstract: Apparatus features a signal processor or signal processing module configured to: receive signaling containing information about an acoustic noise profile that is directly measured and generated by a slurry hitting a probe configured in a part of a cyclone; and determine corresponding signaling containing information about the status of the part of the cyclone, based upon the signaling received. The signal processor or signal processing module is configured to provide the corresponding signaling, including where the corresponding signaling provided contains information about whether the part of the cyclone is damaged or worn. The part of the cyclone is an apex of the cyclone, and the corresponding signaling contains information about the status of the apex of the cyclone.

Abstract: Apparatus features a signal processor or signal processing module configured to: receive signaling containing information about a central air-core of an overflow pipe of a hydrocyclone where fluid flow is concentrated in an outer annular region of the overflow pipe that is against an inner wall of the overflow pipe during a normal operation of the hydrocyclone; and determine corresponding signaling containing information about a collapse of the central air-core of the overflow pipe of the hydrocyclone during an abnormal operation of the hydrocyclone, based upon the signaling received. The signaling contains information about a fluid flow rate of the fluid flow by detecting a change in the magnitude of a force and/or a moment on the probe.

Abstract: Apparatus features a signal processor module that responds to signals containing information about sensed sound propagating through a slurry flowing in part, including overflow pipes, of cyclones operating in parallel on a cyclone battery, and determine corresponding signaling containing information about the performance of individual cyclones based upon the signals received. The signal processor forms part of a non-invasive acoustic-based passive monitoring system having cyclones and sensors attached thereto. The signal processor module provides the corresponding signaling as output or control signaling, e.g., for controlling the cyclone battery.

Abstract: The present invention provides new techniques for non-invasive and real-time measurement of the velocity profile of slurry flow in horizontal pipes, as well as the measurement and trending of pipe wear on slurry lines. In the first case, this information can be used to determine the approach and onset of solid deposition on the bottom of the pipe. Having this information in real time can enable operation at lower velocities or higher solids concentration or both while avoiding solids deposition or plugging and their associated operational costs. In the second case, the present invention uses a permanently or semi-permanently installed ring of conformable ultrasonic transducers clamped onto the outside of the pipe. These transducers are used to measure the thickness of the pipe under their respective locations.

Abstract: Apparatus is provided including a signal processor or signal processing module configured at least to: respond to signaling containing information about particle sizes of solids forming part of a slurry stream being fed with a common feed flow into a battery of cyclones; and determine which combinations of cyclones in the battery produce overflow that has undesirable particle size characteristics using a statistical algorithm or technique, based upon the signaling received. The signal processor or signal processing module provides corresponding signaling containing about which combinations of cyclones in the battery produce overflow that has undesirable particle size characteristics, including control signaling to control the operation of the battery, including information about certain combinations of cyclones to avoid, or preferentially to use, to minimize the total amount of coarse material having the undesirable particle size characteristics produced by the battery.

Abstract: Apparatus for determining a thickness of a wall of a pipe, featuring a signal processing module configured to respond to signaling containing information about traveling stress waves transmitted to and reflected back from a wall of a pipe by a sensor band that includes a series, ring or array having multiple transducers circumferentially arranged and mounted around, and attached to or clamped onto, an outside wall of the pipe; determine a profile of a thickness of the wall of the pipe corresponding to circumferential locations of the multiple transducers based on the signaling received from the sensor band, and the provides corresponding signaling containing information about the profile of the thickness of the wall of the pipe; and another module configured to receive the corresponding signaling and provide a visual indication of either data or a graph of the thickness of the wall of the pipe.

Abstract: Apparatus for determining a thickness of a wall of a pipe, featuring a signal processing module configured to respond to signaling containing information about traveling stress waves transmitted to and reflected back from a wall of a pipe by a sensor band that includes a series, ring or array having multiple transducers circumferentially arranged and mounted around, and attached to or clamped onto, an outside wall of the pipe; and determine a profile of a thickness of the wall of the pipe corresponding to circumferential locations of the multiple transducers based on the signaling received from the sensor band; and one or more orientation or rotation sensors, each responding to its orientation in relation to its displacement on the pipe and to provide an orientation signal containing information about the same.

Abstract: A processor module features a module that respond to input signalling containing information about a volumetric flow of a fluid having minerals and varying amounts of entrained gas flowing in a pipe and being processed in a processing stage of a mineral extraction processing system for extracting a mineral from ore, and provides output signalling containing information about operations of the processing stage of the mineral extraction processing system that is not substantially affected by the varying amounts of entrained gas in the fluid flowing in the pipe. The output signalling controls the operations of the processing stage. The input signalling is based upon a speed of sound measurement, including a SONAR-based entrained gas measurement to determine the amount of entrained air in conjunction with a density measurement of the fluid flowing in the pipe.

Abstract: The present invention provides a processor or signal processing module that features one or more modules configured to receive an input signal containing information about the unsteady pressures or acoustic emissions caused by a medium flowing through a pump, and also configured to provide of an output signal containing information about the performance of the pump. The information about the performance of the pump may include information about pump performance monitoring by a slip flow measurement, about predicting impeller wear, about pump impeller cavitation monitoring, about pump monitoring through acoustic emissions, about pump leak detection, about pump efficiency monitoring and about positive displacement pump monitoring.

Abstract: Apparatus for determining a thickness of a wall of a pipe, featuring a signal processing module configured to respond to signaling containing information about traveling stress waves transmitted to and reflected back from a wall of a pipe by a sensor band that includes a series, ring or array having multiple transducers circumferentially arranged and mounted around, and attached to or clamped onto, an outside wall of the pipe; and determine a profile of a thickness of the wall of the pipe corresponding to circumferential locations of the multiple transducers based on the signaling received from the sensor band; and one or more orientation or rotation sensors, each responding to its orientation in relation to its displacement on the pipe and to provide an orientation signal containing information about the same.

Abstract: Apparatus for determining a thickness of a wall of a pipe, featuring a signal processing module configured to respond to signaling containing information about traveling stress waves transmitted to and reflected back from a wall of a pipe by a sensor band that includes a series, ring or array having multiple transducers circumferentially arranged and mounted around, and attached to or clamped onto, an outside wall of the pipe; determine a profile of a thickness of the wall of the pipe corresponding to circumferential locations of the multiple transducers based on the signaling received from the sensor band, and the provides corresponding signaling containing information about the profile of the thickness of the wall of the pipe; and another module configured to receive the corresponding signaling and provide a visual indication of either data or a graph of the thickness of the wall of the pipe.

Abstract: Apparatus, including a signal processor, featuring at least one module configured to respond to signals containing information about sound propagating through a slurry flowing in part, including overflow pipes, of cyclones operating in parallel on a cyclone battery, and determine the performance of individual cyclones based at least partly on the information contained in the signals.