Scanalyse Technology - Austmine
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Scanalyse Technology - Austmine
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Scanalyse Technology - Austmine
- 1. Scanalyse Technology for Crushers and Grinding Mills Copyright Scanalyse Pty Ltd 1
- 2. Scanalyse and its products • Scanalyse is a technology services company, specializing in comminution processes • Condition monitoring technology for wear components in Mills and Crushers • We help clients make savings in liners costs and grinding media, improve availability and operational performance and reduce energy costs Copyright Scanalyse Pty Ltd 2
- 3. Red Dog Bloom Lake Iron Ore Canada Boliden Highland Valley Copper Climax Phu Bia Kennecott Penasquito Robinson Batu Hijau Round Mountain Choco10 Freeport Ok Tedi Lumwana Los Palembres Mantos Blancos Macraes Carmen de Andacollo Mantos de Oro Esperanza Modikwa Waterval Wagerup Worsley Tanami Kanowna Mc Arthur River St Ives Olympic Dam Century KCGM Prominent Hill Ernest Henry Black Swan Northparkes Mt Isa Zinc Cadia Leinster Cannington Cowal 3 Copyright Scanalyse Pty Ltd
- 4. NO CONFINED SPACE ENTRY Mills: 15-30 minutes downtime Crushers: 0 minutes downtime Traditional Copyright Scanalyse Pty Ltd Scanalyse 4
- 5. Copyright Scanalyse Pty Ltd 5
- 6. Data Processing & Product Deliverables • 3D Model • Wear Report • Flag Report Copyright Scanalyse Pty Ltd 6
- 7. Data from 3D model Liner Profiles Copyright Scanalyse Pty Ltd 7
- 8. Multiple Scans enables Wear Monitoring Copyright Scanalyse Pty Ltd 8
- 9. Wear Curves Copyright Scanalyse Pty Ltd 9
- 10. Reline Forecasting Scan Nov 5, 2007 Reline on Feb 5, 2008 Copyright Scanalyse Pty Ltd 10
- 11. Liner Profiles Copyright Scanalyse Pty Ltd 11
- 12. MillMapper Benefits/ Case Studies Copyright Scanalyse Pty Ltd 12
- 13. Avoid Catastrophic Failure TECK Carmen de Andacollo Copyright Scanalyse Pty Ltd 13
- 14. Extend liner life MMG Century SAG: 30% extra life ERA Ranger Rod mill: 12 months to 16 months reline Copyright Scanalyse Pty Ltd 14
- 15. Ball Charge Los Pelambres: Ball to Ore ratio measurement & correction increases throughput and pays for service after two surveys Copyright Scanalyse Pty Ltd 15
- 16. New MillMapperTM Functionality Ball Size Distribution Copyright Scanalyse Pty Ltd 16
- 17. New MillMapperTM Functionality Open Area Copyright Scanalyse Pty Ltd 17
- 18. CrusherMapper Copyright Scanalyse Pty Ltd 18
- 19. Laser scanning Data collection of several million 3D point measurements using a laser scanner Copyright Scanalyse Pty Ltd 19
- 20. Processed laser scan data Copyright Scanalyse Pty Ltd 20
- 21. Preventing Early Change Out Thickness new concaves Thickness relined concaves Copyright Scanalyse Pty Ltd 21
- 22. CrusherMapper Benefits Data collection can be completed remotely enabling : Completion without any additional downtime Eliminating all safety risks to condition monitoring personnel Eliminating the need for confined space isolation overheads Data covers the entire concave and mantle liners in very high detail Data collection on mantles is possible in situ Liner failures can be detected in situ Copyright Scanalyse Pty Ltd 22
- 23. DEM Modelling The Discrete Element Method (DEM) is a computational method that models particulate systems This is done by following the motion of every particle in the system and modeling all collisions between the particles and the boundary MillMapper scans were imported into the DEM Platform to provide highly accurate profiles for worn liners. 23 Metplant Perth, August 2011
- 24. Scanalyse Technology for Crushers and Grinding Mills Copyright Scanalyse Pty Ltd 24
Notes de l'éditeur
- MillMapper is a product which has been developed by Scanalyse Pty Ltd in conjunction with Curtin University in Perth, Western Australia. Scanalyse has been providing this product to minesites in Australia since 2006 and is the only company worldwide who can provide this service. CrusherMapper was released commercially in 2010 and provides a similar wear monitoring solution for gyratory crushers. This product captures the complete internal conditions of the mill including liners and the ball charge. It enables more accurate forecasting for change out dates for liners meaning that liner life can be extended. Achieving a longer life from liners saves cost but importantly also reduces the number of shutdowns required in a year and therefore reduces downtime. Also alerts operators to potential catastrophic failure. MillMapper is being used in Australia, South East Asia and now in Chile, Bolivia, Peru, Venezuela, USA, Canada.
- The technology used to collect data is a 3D laser scanner shown in the pictures above. If it is mounted on a boom as shown in the pictures in the middle it eliminates the need for confined space entry procedures and results in very fast measurement. It only takes 5 minutes to do a complete scan (which captures 10 million thickness measurements !!). The complete inside surface of the liners is captured rather than just the few points where the man can reach. The picture on the left shows the traditional UTG measurement The picture on the right shows a method of lowering the scanner into the mill through the inspection hatch on top of the mill. This method also eliminates confined space entry procedures.
- Sites where MillMapper has been trialled, showing global nature
- The technology used to collect data is a 3D laser scanner shown in the pictures above. If it is mounted on a boom as shown in the pictures in the middle it eliminates the need for confined space entry procedures and results in very fast measurement. It only takes 5 minutes to do a complete scan (which captures 10 million thickness measurements !!). The complete inside surface of the liners is captured rather than just the few points where the man can reach. The picture on the left shows the traditional UTG measurement The picture on the right shows a method of lowering the scanner into the mill through the inspection hatch on top of the mill. This method also eliminates confined space entry procedures.
- The technology used to collect data is a 3D laser scanner shown in the pictures above. If it is mounted on a boom as shown in the pictures in the middle it eliminates the need for confined space entry procedures and results in very fast measurement. It only takes 5 minutes to do a complete scan (which captures 10 million thickness measurements !!). The complete inside surface of the liners is captured rather than just the few points where the man can reach. The picture on the left shows the traditional UTG measurement The picture on the right shows a method of lowering the scanner into the mill through the inspection hatch on top of the mill. This method also eliminates confined space entry procedures.
- Highlights the 3 deliverables that the client receives. They get much more than a written report.
- Profiles that are embedded in the 3D file. The shape of all the liners can be seen at 100 mm intervals right throughout the mill. I often break off the Powerpoint and go in to the 3D file at this time. It gets them excited.
- Liner wear is also plotted against tonnage. Here we see 2 separate liner lives to enabling comparison of wear if required. It is important to take several measurements for each liner life cycle because more points that are on the wear curve give more information. It is particularly important to get regular measurements towards the end of liner life when wear rates can accelerate. At least 5 measurements per liner life cycle are recommended and more are better.
- A wear curve is reported for every liner segment. In the ball mill case above there are 5 shell liners, a Feed Section Inner and Outer liner and a Discharge Section Inner Liner and Outer. The reline forecasting is done for every liner segment. The failure tonnages and dates are also shown. You can see from the tabs at the top of the slide (Forecasting, Wear, Profiles, Liner Weights, Ball charge) that there is more data that we report on. The following slides describe them briefly.
- Liner profiles can be drawn by looking at the data in cross sections. The profile above is for the Outer Liner of the Feed End section and is at a location 150 mm radially out from the start of the liner. A series of profiles are drawn showing the change over time. This information is very useful for calculating lifter bar angles and determining grinding ball trajectories accurately. The performance of the mill can be correllated with liner shape as well to provide a better understanding of the optimum profile required for best mill performance.
- MillMapper forecasting is more accurate and can be used to more closely predict when liner change out is required. It can also be used to assist in liner redesign so that all liners require changing out at the same time. Extending liner life will bring immediate cost savings in purchasing liners. In a SAG mill where the annual cost is $2M a 10% life extension will automatically bring a $200,000 saving. For a mill which has a 95% availability, increasing the liner life by 10% will reduce down time by 10%. Downtime of 5% per year equates to 18 days. 10% of 18 is 1.8 days. If a conservative factor is applied then at least 1 day or 24 hours of downtime will be saved. Again, at $50,000 per hour 24 hours will bring a $1.2M revenue increase.
- Localized “hot spots” for wear can be easily spotted. You won’t identify these with limited UTG measurements.
- Wear curves showing that liner life extension can be achieved. Two sites in Australia are named who have achieved extended life.
- Ball charge information is captured: Improved accuracy Recorded as a percentage of mill volume Recorded as volume in M 3 Ball Feed rates can be more accurately determined In this case the ball charge was increasing because of incorrect ball addition rates. It was corrected and saved $50,000 p.a.
- Series showing the analysis of the scan for ball size and the results
- Open area image showing raw scan data. Can clearly see pegged holes.
- Mention that we don’t need to be down in the dump pocket when we use a frame. It takes less than an hour to capture scans.
- The two pics show that this concave was relined when it had hardly worn. It had a lot of life left in it. The blue bands haven’t changed colour very much.
- MillMapper is a product which has been developed by Scanalyse Pty Ltd in conjunction with Curtin University in Perth, Western Australia. Scanalyse has been providing this product to minesites in Australia for more than 3 years and is the only company worldwide who can provide this service. This product captures the complete internal conditions of the mill including liners and the ball charge. It enables more accurate forecasting for change out dates for liners meaning that liner life can be extended. Achieving a longer life from liners saves cost but importantly also reduces the number of shutdowns required in a year and therefore reduces downtime. MillMapper is being used in Australia, South East Asia and now in Chile and Peru. It is in use at El Teniente, Candelaria, Collahuasi, Los Broncos and Yanacocha and a proposal for a trial is being considered by Sossego.