Direct particle size
Outokumpu Technology Minerals Processing
Courier® 6 SL
Particle size monitoring and control
improves both throughput and grind in
the grinding circuit. It also improves
the downstream process by minimizing
reagent consumption, increasing
recoveries and making thickening/
filtration more effective.
The Particle Size Instrument PSI 200 is an on-stream slurry particle
size analyzer for mineral processing plants. Its measurement
principle is based on a direct measurement of particle size using
a high precision automatic caliper. The instrument requires
a representative 70–170 liters/minute sample from the process
stream. The measurement result is displayed locally on a large
display and sent out as a 4–20 mA instrument signal or serial line
using Modbus RTU protocol. There are two major versions of the
instrument: single stream and a multi-stream unit. Several options
are available for primary sampling, density measurement and
remote display of results on a PC.
“Since the installation of PSI 200 we have been
able to control very close to our target grind. Our
gold recovery has increased from 94.5 to 96. The
investment paid itself back in two months.”
Water To Flotation
Ore Silos Particle Size
Feeders Speed Belt
DT density measurement
DC density control
FT flow measurement
FC flow control
JT power measurement
LT level measurement Load Cell
LC level control
Power Variable Speed
PT pressure measurement Pump
WT weight measurement
WC weight control
A critical variable for grinding circuit control is the PSI 200 can be used in regrind circuits as well,
product particle size. Particle size measurement because the instrument is not sensitive to entrained
from cyclone or other classifier overflow is the air in sample.
industry practice today.
Information from particle size and other on-line
The PSI 200 Particle Size Instrument provides real- instruments is used for closed loop and expert
time and accurate particle size and slurry density system control. Outokumpu has long experience in
measurements. providing advanced control solutions for grinding
circuits. Example on the left shows a typical
Proscon ACT expert system program.
Low capacity Losses in coarse
Losses in fines Poor liberation
and air bubbles from the continuously
flowing sample that is fed to the PSI 200
sensor by gravity. The PSI sensor head has
the direct particle size gauging mechanism.
The gauge position is measured by a
Sampling highly accurate electronic position sensor.
Representative sampling is an essential
requirement for dependable particle size The PLC based digital electronics converts
measurement. Static Outokumpu LSA, the scanning caliper measurements into two
NLA, PSA and two stage CPS samplers 4–20 mA output signals per measured Optional Windows based operator station
provide a proven maintenance free solution. stream. These signals correspond to a displays, reports and stores particle size and
Sampler control option has programmable particle size screen-class, such as percent diagnostic information from one or several
flush and trash removal (NLA) functions. passing 74 microns. The same information networked PSI 200 instruments.
is also displayed on the instrument’s digital
Particle size measurement display panel.
PSI 200 Particle Size Instrument is an
on-stream analyzer for measuring size Calibration
distribution of particles suspended in slurry. The PSI 200 is calibrated by measuring a
Particles in the size range 25–500 mesh series of samples and correlating the sensor
(500–25 µm, with ultrafine option down to signal readings with respective laboratory
5 µm) can be measured. A primary sample screen analyses. When the automatic
flow of between 70–170 l/min (50–300 calibration procedure is initiated, sensor
l/min max range) is reduced to a stable 10 readings are saved and the sample measured
l/min flow. A trash screen and level control by the sensor is diverted by the calibration Additional particle size fractions can be
are used to remove trash, oversize particles sampler into a sample bucket. calculated and displayed by the operator
station if required. PSI version of optional
A quick calibration requires only a couple Outocal calibration tool is available to help
of samples. A range of approximately 20 with the calibration of the instrument.
samples is required to get an accurate
calibration equation. Calibration models PROSCON® or other process control
and system configuration parameters are system can read the particle size information
entered through a keyboard on the from 4–20 mA signals or optional serial
electronics cabinet or operator station. Due DCS interface.
to the direct size measurement and
automatic zero check, calibration stays Windows is a trademark of Microsoft Corp.
stable over a long period of time.
Slurry density measurement is available as
an option for the PSI 200. It is based on the
proven principle of weighing a fixed volume
of slurry using a sensitive high precision
Compact single frame instrument is
installed and operating in a day after
The smart way to measure particles:
Precision Precision Precision
position position position
sensor sensor sensor
WATER SLURRY SLURRY
1. Reference check 2. Sample 3. Measure
The PSI 200 instrument measures directly a large number of particles from a representative sample. The measurement uses
a high precision ceramic tipped sensor measuring the size of randomly selected particles. The sensor sends the information to
a PLC, which converts it to calibrated percent readings passing the selected mesh or micron sizes. The result is updated once
per second based on 120 measurements performed during the past 60 seconds.
Direct particle size measurement has the
■ Reference measurement eliminates drifts automatically.
■ Not sensitive to slurry viscosity, temperature or density
variations. Calibration is valid over long periods of time.
■ Air bubbles and flaky minerals (mica for example) do not
confuse the instrument. Froth in regrind applications is
not a problem.
■ Expensive and maintenance intensive sample preparation
is not required to remove air, demagnetize or dilute the
PSI 200 readings are typically within 1–2% absolute error
when compared with accurate laboratory screening results.
Analysis method Slurry density meter option Instrument air
High precision automatic caliper. Measurement is given as density (g/l) or Pressure 5–10 bar (75–145 psi) 7 Nl/min
Percent Solids (%). Absolute 1 sigma (025 SCFM) average consumption, 12 mm
Number of sample streams accuracy is typically for density 5 g/l and for (0.5 inch) flexible tube connection.
One for single stream, 1–3 for multi-line solids by weight 1% unit.
model. Power supply
DCS connection option Single phase 115/230 VAC +- 10%, 50/60 hz,
Sample requirements Point to point serial line connection, based 250W connected to a fused terminal strip.
Sample flow rate 70–170 l/min (18.5 to 45 on MODBUS RTU protocol for reading
US gpm). Sample flow rate is measured. Operating ambient temperature at
measurement results and operational status
Slurry inlet OD - 60 mm (2.4 inch) Slurry sea level
of particle size indicator and density meter.
outlet OD - 76 mm (3.0 inch). Galvanically isolated RS422/RS485-four +5–+40°C (41–104°F)
wire terminal strip connection.
Built-in calibration sampler Storage temperature
Outlet OD - 50 mm (2.0 inch). Non-Plug Launder (NLA) Primary -25–+60°C (-13–140°F)
sampler control option
Composite sampling Environmental classification
Fully integrated automatic cleaning operation
Integrated to calibration sampler in single Analyzer multiplexers, probe and probe
of the NLA-type primary sampler.
stream instrument, integrated to multiplexer control set, IP56 (designed to meet NEMA
in multi stream instrument. Salt water option 4X). Vibration max 10 m/s2 at frequencies
Special materials for high salinity slurry or 45–80 Hz.
Two user definable size fractions. Operator Shipping and installed weight
Station can calculate and display more Operator station option Single-line gross 330 kg (730 lb), net 250 kg
fractions. Windows based software for displaying, (550 lbs).
storing and reporting data (measurements, Multi-line gross 430 kg (950 lb), net 280 kg
calibration measurements, and alarms) from (616 lbs).
Continuous with one second update up to 3 PSI 200’s. The Operator Station can
frequency for single-line, 6–8 minutes for calculate two additional and is able to ISO 9001 quality assurance
multi line unit. display 4 size fractions and density per Outokumpu Technology Mineral Processing
stream. Most run time parameters can be is ISO 9001 accredited and has a rigorous
Particle size range
defined from Operator Station. quality management policy to ensure that
28–500 mesh (600 µm - 25 µm), with
ultrafine option down to 5 µm. Outocal calibration program option
the quality expectations of customers are met.
Regression analysis program designed for The Analyzer has certification.
on-line particle size analyzer calibration.
For particle size fraction 1 sigma accuracy is
typically 1–2 % absolute units. Installation requirements
2500 (W) x 1600 (D) x 3500 (H) mm
2 x 4–20 mA (shielded pair) per stream
(plus one for density option), 9 contact 99 x 63 x 137 inches.
outputs for single-line, 12 for multi-line Multi-line:
unit. 2500 (W) x 1800 (D) x 3500 (H) mm
99 x 71 x 137 inches.
LSA series Launder Box Cutter Sampler. Flushing water
NLA series Launder Box Cutter Sampler Sand filtered raw water, 4–6 bar (58–87 psi)
with automatic, cutter cleaner. PSA series 30 l/min (8.5 gal/min) during flush and
Pressure pipe Sampler to be used at pump zero check cycle, which is typically set for
discharge. length of 1 min. once in a shift Water inlet
OD - 25 mm (1.0 inch).
Single-line model 1750
These specifications refer to the new PSI 200
models 1750 and 2750, where density meter option
does not increase height.
Specifications are for a typical configuration and
project scope only. Actual scope and performance
data does vary according to individual plant and
project specifications and product variations.
Please see the product data sheets and other
documentation for details.
Multi-line model 2750
OD 60,3 mm
Max 1445 mm stabilization
Control cabinet Cap. 300 l/min
and user interface OD 76,1
2-6 bar ~30 l/min
25 mm hose connector
Cap. 20 l/min max.
OD 50 mm
Outokumpu has long and broad experience in the recovery
and refining of base metals. The company has developed
a comprehensive line of metallurgical processes and
related advanced equipment, from grinding to metal
production. Outokumpu TankCell® technology is used by
major mining companies around the world. State-of-the-art
on-stream analyzers and automation systems have been
used in Outokumpu’s concentrators and refineries since the
late 1960’s. The company is the market and technology
leader with more than 700 on-stream analyzer systems
delivered to mineral processing and metallurgical
Worldwide sales and service:
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