Measuring Systems and Process Optimisation for the Mining Industry

Güstener Straße 72,
52428 Jülich,

KIMA specialises in high-performance analogue and digital closed-loop controls, innovative sensor systems and databases for the minerals, cement, chemistry, oil exploration, food, and mechanical engineering industries.

The central idea and main target of KIMA is the optimisation of industrial process towards more efficiency, more productivity and less environmental pollution.

Innovative sensor systems, closed-loop controls and databases

With SmartFill, the ‘electronic ear’, KIMA has set new patterns regarding the precision and reliability of measuring the fill level of ball mills. Based on the great results received with the SmartFill system, KIMA has developed its predictive expert system SmartControl.

This software tool has a modular structure and enables plants to use their own strategy for controlling nearly every industrial process. With MillMaster, KIMA created a specialised version of this software tool for closed-loop control of grinding circuits. MillMaster comes with different technology modules (e.g. for ball mills, vertical roller mills, roller presses, etc.) developed by KIMA and based on its great experience with optimisation of grinding processes.

Fill level measurement for ball mills

In contrast to all existing classical methods of ball mills’ fill level measurement SmartFill is the only system which measures the sound directly where it occurs: on the mill shell.

Whilst the classical methods (e.g. microphones, base or bearing mounted sensors etc.) have to struggle with a lot of problems (such as interference by noise of other mills / machines, ambiguous location of sound origin, dust, etc.), none of these problems exist when using the SmartFill solution. SmartFill provides plants with previously unavailable information and thus provides a great deal of advantages. These include:

  • Interference-free measurement – no influences from other mills or machines nearby
  • Significantly enhanced precision of measurement
  • Reliable and precise measurement of the fill level of both chambers absolutely independent from each other
  • More stable operation of the ball mill possible and thus enhanced throughput, less wear-out and more even product quality (fineness)
  • Self-powered system due to integrated generator – no mill stop necessary for changing any batteries

Customised control strategies for industrial processes

Due to its modular design, SmartControl allows the customised implementation of control strategies to nearly every industrial process. SmartControl comes with more than 120 blocks, including: digital filters, bit-field manipulations, programmable blocks, classical closed-loop controls (PI, PID) and free programmable calculation blocks. By connecting different blocks, integrated groups can be created individually and thus control can be applied to the relevant process.

Predictive control of grinding processes

MillMaster can control grinding circuits both fully automated and unattended, and, with one MillMaster system, up to six mills can be operated at optimum status. At the same time, the availability of the grinding facility increases due to protection of the system against overfilling or similar malfunctions.

Keeping the fill level at a constant optimum level leads to smooth operation which significantly results in less wear-out and a more homogeneous product. The production increases while the specific energy consumption decreases.

Integration of grinding circuit control systems

MillMaster can be integrated with any automation system, connecting via a standard interface (OPC) and optimising the process without changing the formerly existing control system. This means the old controls can be reactivated immediately at any time

The Millmaster system can be customised using our pre-designed modules which relate to the part of the grinding process that needs to be controlled such as vertical or ball mills, roller presses, separators, hot gas generators, water injectors and ventilation systems.

Due to its modular design, customisability and extensive bundle of functionalities, MillMaster provides a number of great advantages for grinding facilities. These include:

  • Higher energy efficiency
  • Increased production
  • Improved product fineness
  • Less wear-out
  • Higher facility availability
  • Reduced maintenance costs

Vibration velocity sensor for monitoring bearings and plants

V-Sens is KIMA’s innovative solution for monitoring rotating machines and bearings such as fans, turbo-engines, mills, kilns, classifiers, cylones and drives.

The V-Sens consists of an M12 screw and can be easily mounted. All electronics are included within the M12 screw, allowing the sensor to be connected directly to any automation system without any further external electronics.

The V-Sens features a self-testing function which can be initiated by a digital signal from your automation system. The sensor is available for radial or axial direction of measurement and can be adapted to nearly any rotating machine. The standard version measures vibrations in the range of 10Hz – 100Hz; however, customised versions for other frequencies are also available.

Contract-based development of proprietary products

KIMA has a great deal of experience in developing products and strategies in the fields of high-precision measurements, predictive controls, all kind of sensors, etc. for other companies based on OEM contracts. In this business field KIMA is able to look back on many product developements, such as metal detectors, control systems for oil rigs/drills, and specialised sensor systems.

KIMA Echtzeitsysteme GmbH

Güstener Straße 72

52428 Jülich


Mr Alexander Scholl, sales manager +49 2463 9967 64 +49 2463 9967 99