Mining

Advanced Spiral Automation for Coal and Mineral Processing

Overview

Spiral separators are widely used throughout the mining and coal preparation industries to improve product quality by separating material streams based on density and particle characteristics. Despite their importance, spiral circuits have historically remained one of the last areas of many processing plants to rely heavily on manual adjustment.

Vanadium Group identified an opportunity to modernise this process through automation. Their vision was to create a system capable of continuously monitoring process conditions and automatically adjusting spiral splitter positions to optimise recovery and product quality.

To bring this concept to life, Vanadium partnered with Hetech to design, develop and manufacture the electronic control platform that would become a core component of the Spiral Galaxy Automation system.

The Challenge

Traditional spiral circuits rely on manually adjusted splitters that determine where material is directed as it exits the spiral. In coal preparation and mineral processing plants, feed characteristics can vary significantly throughout the day due to changing ore properties, particle size distribution and process conditions.

While modern plants have automated many other circuits, spiral splitters are often adjusted infrequently because operators may be responsible for managing dozens, or even hundreds, of spirals across a site. As process conditions change, splitter settings can become sub-optimal, potentially impacting product quality, recovery rates and operational efficiency.

Vanadium sought to eliminate this limitation by creating an automated system capable of:

• Continuously analysing material quality in real time.
• Automatically positioning spiral splitters with high precision.
• Integrating with existing plant control systems.
• Reducing the need for manual intervention.
• Providing operators with greater visibility of process performance.

The system also needed to be robust enough to operate reliably within the harsh conditions typically found in mining environments.

Hetech’s Solution

Working closely with Vanadium’s engineering team, Hetech designed and manufactured the electronics platform that enabled the automation of spiral splitter control.

The solution integrated Vanadium’s Delta Optic Analyser technology with an intelligent actuator control system. Material quality data was analysed in real time and used to determine the optimum splitter position for each spiral. Electronic controllers developed by Hetech then drove the linear actuators responsible for physically adjusting the splitter position.

Instead of relying on occasional manual adjustments, the system could continuously respond to changing feed conditions and automatically direct material to the appropriate recovery stream.

The platform was also designed to integrate with site SCADA and control systems, providing operators with:

• Real-time process visibility.
• Remote control capability.
• Performance monitoring and data logging.
• Automated control of splitter positioning.
• Continuous operational feedback.

This transformed the spiral circuit from a largely manual process into a digitally connected and automated part of the plant.

Engineering & Development

As part of the project, Hetech delivered a wide range of engineering services, including:

• Embedded Linux platform development.
• Electronic hardware and circuit design.
• Motor controller development.
• Automation system integration.
• Prototype development.
• Bench testing and field testing.
• Industrial design support.
• Software development.
• Assembly and production support.
• Bill of Materials (BOM) management.

Hetech worked alongside Vanadium through the development and refinement phases, helping transition the concept from prototype testing through to deployment-ready hardware suitable for mining operations.

The Outcome

The resulting Spiral Galaxy Automation system enabled mining operators to automate one of the last largely manual areas of plant operation.

By combining real-time process analysis with automated actuator control, the system provided:

• Reduced manual intervention by plant personnel.
• Faster response to changing feed conditions.
• Improved process consistency.
• Greater visibility through plant control systems.
• Reduced operational risk associated with manual adjustments.
• The potential for improved recovery and feed quality outcomes.

The technology has since been deployed within Australian mining operations, demonstrating how automation can be applied to traditionally manual mineral processing activities.

Key Capabilities Delivered

• Field deployment and testing
• Mining automation system design
• Embedded electronics and controller development
• Linear actuator control systems
• Real-time process integration
• SCADA connectivity
• Industrial automation hardware
• Prototype to production support

Client Testimonial

“We partnered with Hetech’s engineering team to design and build a mining automation system to be integrated into gravity-fed spiral circuits. Their customer service and professionalism have exceeded my expectations. They consistently deliver within timeframes and even fly out engineers to assist with diagnosing and maintaining products in the field, ensuring the system was operating as expected. I highly recommend Hetech; they have gone beyond their expectations to ensure the best product possible.“

Gerald Van Niekerk
Director, Vanadium Group

Developing a new mining technology?

Whether you’re refining a prototype or preparing for commercial production, Hetech can help optimise your product for manufacturing, improve production efficiency and support a successful market launch.

Contact Hetech to discuss your next mining innovation project.