Online mass-flow-rate measurement of high-intensity gas-conveyed particle flow for dry mineral processing

Measuring the mass flow rate of high-intensity gas-conveyed particle flow (GCPF) in real time is of great importance for enhancing efficiency and productivity in dry mineral processing circuits. It also poses challenges beyond the capability of most existing technologies. In this article, we introduce a novel, cost-effective, online mass flow rate measurement system utilizing a force transducer. A theoretical model of the relationship between the average impact force and the mass flow rate was developed using the Hertz theory of impact. A prototype sensing system was then designed and constructed, followed by a series of experiments to validate the theoretical model. The experimental results corroborated the proposed model and showed the accuracy of the measurement was within 2% for mass flow rates above 1.741 g/s. This demonstrated the system’s capability to measure the mass flow rate of GCPF in real-time using measurements of the average impact force. • A prototype is developed to measure the mass flow rate of GCPF in real-time. • A model is derived, linking the force measurement to mass flow rate. • The measurement accuracy is investigated, under the effect of the probe resonance. • Experimental results show promising accuracy, with errors around 2%.