Online Analyzer& Process Optimization for Mineral Processing & Metal Refinery

Provide online measurement and process optimization solutions for the ore processing and metal smelting industries

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Online Analyzer& Process Optimization for Mineral Processing & Metal Refinery

Provide online measurement and process optimization solutions for the ore processing and metal smelting industries

View more +

Online Analyzer& Process Optimization for Mineral Processing & Metal Refinery

Provide online measurement and process optimization solutions for the ore processing and metal smelting industries

View more +

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ABOUT US

We are an online process instrument and automation control systems supplier, specializing in the R&D, design, manufacturing, sales and services of online instruments and sensors. Since its establishment, the company has been focused on the process industries, with a particular focus on mineral processing and metal refinery.

We provide a comprehensive range of solutions tailored to industry-specific characteristics, as well as the challenges and pain points encountered in various applications. For example, we provide sonar-based flow and gas-content measurement systems, systems for measuring the mud layer interface and tank cross-sections, non-radioactive clamp-on density meters, online ore-grade analyzers, online NK concentration meters, and online RP/aK measurement systems. These solutions help customers effectively address process conditions characterized by high temperatures, scaling tendencies, corrosiveness, and erosive environments. Leveraging globally leading sensor technologies and closely collaborating with customers to understand their specific application scenarios, we develop both software and hardware solutions, delivering customized offerings that meet the needs of the ore-processing and metal-smelting industries.

We help our clients optimize production metrics, reduce operational costs, and increase output. We serve the vast majority of global leaders in the ore processing and alumina industries, with our products being used worldwide—including in Australia, China, Canada, the United States, Jamaica, Chile, Brazil, Peru, Mexico, Mongolia, Indonesia, Vietnam, Fiji, Myanmar, India, South Africa, Guinea, the Democratic Republic of the Congo, Sierra Leone, Madagascar, Ireland, Spain, Greece, Norway, Sweden, and more.

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Measurement of Caustic Soda Concentration in Sodium Aluminate Solution

Based on the chemical characteristics of sodium aluminate solutions and integrating technologies such as optics and electrochemistry, we have developed a proprietary model for sodium aluminate solutions. This model enables precise measurement of alkali liquor concentrations throughout the entire Bayer process for alumina production. Tailored to the specific application requirements of different process stages—such as scale formation and slurry erosion—we have custom-designed alkali liquor line measurement systems equipped with automatic cleaning mechanisms, as well as specialized ceramic and hydrodynamic sensors for slurry monitoring. Accurate, real-time, and continuous measurements significantly reduce reliance on laboratory sampling analyses and mitigate delays and control shortcomings associated with traditional methods. Prolisen offers comprehensive solutions leveraging these sensors to automate both leaching and evaporation processes. To date, our solutions have been installed in over 1,000 facilities across countries including Australia, China, Brazil, Indonesia, Dubai, Saudi Arabia, Vietnam, and India.

Measurement of Caustic Soda Concentration in Sodium Aluminate Solution Slurry

Based on the chemical characteristics of sodium aluminate solutions and integrating technologies such as optics and electrochemistry, we have developed a proprietary model for sodium aluminate solutions. This model enables real-time measurement of alkali liquor concentrations throughout the entire Bayer process for alumina production. Tailored to the specific application requirements of different process stages—such as scale formation and slurry erosion—we have custom-designed alkali liquor measurement systems equipped with automatic cleaning mechanisms, as well as specialized ceramic and hydrodynamic sensors for slurry applications. These precise, real-time, and continuous measurements significantly reduce reliance on laboratory sampling analyses and mitigate the drawbacks associated with delayed control. Praisen offers solutions that leverage these sensors to automate both digestion and evaporation processes. We have installed our systems in over 1,000 facilities across countries including Australia, China, Brazil, Indonesia, Dubai, Saudi Arabia, Vietnam, and India.

Sodium aluminate solution RP/αK measurement

Based on the chemical characteristics of sodium aluminate solutions and integrating technologies such as optics and electrochemistry, we have developed a proprietary model for sodium aluminate solutions. This model enables real-time measurement of RP/αK concentrations throughout the entire Bayer process for alumina production. Tailored ceramic and hydrodynamic designs of slurry sensors have been specially developed to meet the application-specific requirements of different process stages, including scale formation and slurry erosion. Accurate, real-time, and continuous measurements significantly reduce reliance on laboratory sampling and analysis, as well as the drawbacks associated with delayed control. Prolisen offers solutions that leverage these sensors to automate both leaching and evaporation processes. To date, over 500 installations have been carried out in countries including Australia, China, Brazil, Indonesia, Dubai, Saudi Arabia, Vietnam, and India.

Mud Layer Interface Meter

The Praisson Sludge Layer Interface Instrument is an intelligent measurement system integrating multiple measurement functions. The measurement parameters include: The Praisson Sludge Layer and Tank Profile Measurement System provides the following measurement indicators for the alumina separation and washing process: liquid level height, clear liquid layer height, turbidity of the clear liquid layer, caustic soda concentration in the clear liquid layer, settling layer height, and sludge layer height. By delivering precise measurements and outputs, this system also enables the implementation of an automatic control system for sedimentation using the Praisson Sludge Layer Interface Instrument. Unlike non-contact methods (which rely on temperature measurements to determine sludge levels), the contact-based method uses the turbidity of the clear liquid layer to monitor the turbidity of the overflow liquid in real time online. Additionally, by measuring the height of the settling layer and the clear liquid layer and setting alarm thresholds, this method effectively prevents the tank from becoming cloudy due to overflow. Real-time measurement of the settling layer height allows for automated adjustment of the flocculant dosage, significantly optimizing the amount of flocculant added. Measurement of the caustic soda concentration in the clear liquid layer enables real-time monitoring of the caustic soda concentration in the overflow liquid, which is crucial for controlling the efficiency of subsequent decomposition processes.

Sonar flow meter

The SONARtrac sonar flowmeter, an online measurement system for volumetric flow rate and entrained gas content, represents an innovative breakthrough in full-bore, non-invasive flow measurement technology. By installing a set of sensors on existing pipelines and leveraging patented passive sonar processing technology, the system “listens to” and analyzes the acoustic signatures of turbulent fluid flow within the pipeline, thereby enabling precise measurements. This technology was developed specifically for flow measurement under the most demanding operational conditions—such as drilling, oil and gas extraction, as well as in three-phase flows involving solids, liquids, and gases, including ore processing and metal smelting.

Non-nuclear impact density meter

Andymer’s proprietary tapping technology generates, acquires, and analyzes vibrations on pipe walls to determine the density of the slurry inside the pipes. Intelligent software distinguishes between valuable vibration signals and ambient vibrations, thereby capturing the unique signature generated by the slurry. Advanced algorithms enable real-time, high-resolution spectral analysis, ensuring highly sensitive and accurate measurements. Compared to radioactive density or ultrasonic density technologies, this technique offers significant advantages: lower maintenance costs, non-contact operation, compatibility with metal or plastic pipelines of any size, no need for routine maintenance, quick installation within minutes, and no disruption to production.

Ore grade analyzer

The emergence of SFA’s near-infrared technology stems from the market’s demand for alternatives to conveyor-belt PGNAA sensors. As the industry’s first provider to apply near-infrared technology to online analysis of both organic and inorganic raw materials, we have been delivering elemental and phase-specific online analysis for over a decade to the metal smelting and ore-processing industries, combining highly sensitive analytical methods with reliable and precise sensors. The rapid advancement of Advanced Process Control (APC) has highlighted the outdated state of quality control in the mineral resources sector, which still largely relies on manual sampling—a practice that is severely lagging behind. Leveraging big data and artificial intelligence technologies, SFA has developed highly sophisticated calibration models for real-time measurement of mineralogical and chemical compositions. This approach is not only accurate and versatile but also free from nuclear safety concerns.

Online particle size analyzer

The ore grade analyzer PST is a novel and highly versatile technology that is installed on the overflow slurry pipeline of a single hydrocyclone. It is the only system capable of directly and in real time measuring the particle size of the overflow from an individual hydrocyclone. This online measurement provides a reliable, low-maintenance method for determining particle size distribution, enabling systematic optimization of grinding operations. The value of this technology lies in its ability to track the particle size of the overall hydrocyclone group’s overflow based on the contribution of each individual hydrocyclone. As a result, real-time closed-loop grinding control strategies can enhance mineral recovery and improve grinding efficiency while maintaining or even increasing plant throughput. The probe is inserted directly into the hydrocyclone pipeline; it contains no moving parts, requires no sampling, and eliminates the need for complex online sample-handling systems, thereby significantly reducing maintenance requirements.

Multi-component measurement of sodium aluminate solution

This technology, custom-developed for the phase analysis of sodium aluminate solutions, enables fully automated multi-component concentration measurement of sodium aluminate solutions without the need for titration, dilution, or reagents. It represents a groundbreaking instrument that revolutionizes the traditional chemical titration method for liquid-phase aluminum oxide analysis. Equipped with a fully automatic robotic arm, this instrument can simultaneously and automatically analyze a wide range of liquid-phase parameters in a single measurement, including total aluminum oxide, caustic alkali, total alkali, RP, organic carbon, oxalate, and density. In rapid mode, each sample requires only 5 minutes. The instrument features an automated operation process, a compact design that takes up minimal space, robust construction for long-term durability, and low maintenance requirements.

KEMTRAK products

China is the exclusive supplier of high-performance industrial photometers, fluorometers, and turbidimeters manufactured by Kemtrak. These products are easy to operate and require no maintenance. They are widely used in industries such as biotechnology, pharmaceuticals, food and beverage, petrochemicals, and pulp and paper—for example, the DCP007 series photometers are used for color and concentration measurements; the TC007 is designed for turbidity measurement; and the FL007 is an oil-water analyzer.

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Industry Applications

The company continuously pursues technological innovation, actively collaborates with upstream and downstream partners, and strives to enhance its mining applications. At the same time, it places great emphasis on cooperation with other leading instrument manufacturers around the world, providing online process analytical instruments for a wide range of industries—including alumina production, ore processing, dredging, and other process analysis applications.

Solution

Leveraging globally leading sensor technology and custom-developed software applications, we provide industry-specific solutions that meet the needs of the ore processing and metal smelting sectors. We help our clients optimize production metrics, reduce operational costs, and increase output, successfully serving the vast majority of global leaders in the ore processing and alumina industries.

How to use real-time guidance in alumina production for raw material blending and ore allocation

In alumina production via the Bayer process, the objective of “raw material blending” is not to achieve the highest grade but rather to operate the digestion, precipitation, and calcination systems steadily within their optimal operating windows at the lowest overall cost.

Online measurement of bauxite grade has been achieved.

Online measurement of bauxite grade (including Al₂O₃, SiO₂, Fe₂O₃, etc.) is highly valuable in both mining operations and the alumina (Bayer process) production chain; however, it is also widely recognized as one of the most challenging analytical tasks to achieve accurate, long-term stability.

In the alumina industry, flow measurement challenges caused by scaling.

In the alumina Bayer process, scaling—also known as fouling or scale deposition—poses a highly typical challenge to flow measurement. Measurement deviations directly undermine the precision of process control, rendering production automation unattainable. Despite attempts to employ various flow‑measurement technologies, none have succeeded in resolving this issue.

Serve customers

Address:

Building 21, Yangtze Headquarters Base, No. 5 Puzhu North Road, Jiangbei New Area, Nanjing City

Phone:+86 025 58234466\52701863

Email:sli@plapl.com.cn

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Alumina

Ore processing

Dredging

Other process industries

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