The FCB Opti-Bmill™ is a modular intelligent system developed by Fives for the on-line optimization and automated control of ball mill grinding circuits in cement and minerals processing plants. It directly integrates with the existing PLC or DCS infrastructure and continuously regulates mill operating parameters — recirculation flow, acoustic emissions (electronic ears), absorbed power, separator air flow, and elevator power — according to the active product recipe and target fineness.

How does the system optimize grinding in real time?

The Opti-Bmill™ executes five core control functions simultaneously. A recipe management module pre-configures all operational setpoints per product type. The product load and ball load optimization loops maintain the mill at its most efficient fill level by interpreting acoustic sensor signals and power draw. An integrated on-line particle size analyzer enables closed-loop fineness control — the system automatically adjusts separator speed and circulation load to hold the target particle size distribution. A theoretical production rate is computed in real time from the current operating point, giving operators a continuous productivity reference.

What connectivity and data management does it offer?

The system integrates with the plant's existing PLC or DCS via standard industrial communication interfaces. All process data — sensor readings, control actions, alarms, and production rates — is recorded to an on-board historian for trending, reporting, and troubleshooting. Remote monitoring is supported, allowing off-site process engineers to review live performance and historical trends. When combined with Fives' COSMA™ continuous on-stream mineral analyzer, the system extends its control envelope to mineralogical composition in real time.