MINE MAINTENANCE
Aura IQ uses Ava ’ s fibre-optic technology ( FFT Aura Ai-2 ), combined with Mining3 ’ s advanced patented signal processing algorithms and data analytics , to acoustically monitor and assess conveyor health via cloud-based analysis , reporting and alerts
broad range of individuals involved ,” Hames said .
At the end of each trial , an FFT technician carries out a feasibility and return on investment ( ROI ) calculation in partnership with site personnel to assess the potential of Aura IQ against five key performance indicators ( KPIs ).
The company has completed three such trials to date with eight currently underway . The most recent trial completed was at the site of a “ multi-national ” mining company , resulting in the following outcomes : n KPI success outcomes – 92 % ( all POVT KPIs successfully achieved ); n Annual cost savings with Aura IQ installed – $ 5.11 million ; n Efficiency gains – 4 %; and n ROI – 5.4 months .
Other tangible gains included an annual cost reduction in personnel maintaining the conveyor set of $ 475,000 ; an annual cost benefit of extending roller life of $ 212,000 ; reduced time inspecting conveyor set of 152 hours a year ; reduced redundant roller changeout of circa-7,440 rollers / y ; and reduced power consumption due to decreased roller resistance and roller optimisation of $ 59,000 .
Hames concluded on the benefits for end users : “ First , Aura IQ optimises site production by reducing unplanned downtime and anticipating issues ‘ before ’ they occur .
“ Secondly , Aura IQ mitigates risk and enhances occupational health , hygiene and safety management . Aura IQ reduces on-site safety risks and fire prevention by proactively detecting and tracking roller bearings failure progression ( including the build-up of heat related issues ).
“ Finally , with Aura IQ , ‘ condition monitoring ’ advances are becoming ‘ health monitoring ’ ( diagnostic / prognostic ). The system is a simple , reliable step change to a conventional labourintensive approach . The system automatically collects and processes critical conveyor data , and then reports the results immediately either directly on-premise ( data integrated into a site ’ s own SCADA / maintenance system ), or more flexibly via a dedicated
Aura IQ Cloud Reporting Dashboard , providing deep insights accessible anywhere in the world .”
Belt cleaner monitoring
Martin Engineering is all too aware of conveyor health issues , with the bulk material handling solutions provider coming up with many products to improve the productivity and safety associated with operating these ore and waste transporters .
It recently announced a conveyor belt cleaner position indicator that monitors the blade , tracking and reporting remaining service life of said cleaner .
The Martin N2 ® Position Indicator ( PI ) constantly assesses primary belt cleaner blades , notifying Martin service technicians and plant operations personnel when re-tensioning or replacement is required and / or when abnormal conditions occur . The PI can be part of a new installation or directly retrofitted to existing mainframes that use the company ’ s replacement blades , Martin Engineering says . Managers and service technicians can quickly access information on any networked cleaner via cell phone .
Position indicators can be mounted anywhere from 3-800 m from the cellular gateway and the robust , sealed construction means it is virtually immune from damage , according to the company . Up to 50 units can be monitored by a single gateway connecting to the internet , usually located at the highest point in the plant where the cell signal is strongest . The system does not require a cellular line for each PI , instead communicating via radio frequency from each sensor to the gateway .
Operating independently of any plant communications infrastructure , the small physical size and low power requirements deliver a projected battery life of two years .
Martin says the self-contained model was developed to minimise the dependency on in-plant resources , with only the gateway requiring a constant 110 V power point .
WRM patch ups
LANXESS Urethane Systems ’ products have come to the rescue of damaged conveyor belts on many occasions over the years .
Its polyurethane systems can meet mining ’ s demands at the same time as providing superior abrasion resistant solutions that surpass the
performance of ceramics , rubbers , epoxies , engineering plastics and hardened metals , according to the company .
For more than 30 years , WRM ( Wear Repair Material ) 80T has been a repair solution for the mining and quarrying industries . This product served as a basis for the development of the new WRM Premium systems , which are available in 65 and 80 Shore A hardness .
The WRM 80 T Premium and 65 T Premium have a superior environmental health and safety profile compared with conventional technologies ; higher impingement and sliding abrasion resistance ; improved flex / fatigue life ; good chemical resistance ; and a simple application process that enables a rapid return to service of the repaired equipment , the company says .
They come with high rebound properties that exceed 60 % and , in combination with increased tear strength , improve the impingement and sliding wear properties by 30 % compared with the WRM 80T , LANXESS added .
“ Most elastomeric mining applications have some level of flex in the component operations and flex fatigue failures can be sudden and costly ,” the company said . “ The new WRM Premium systems have a 200 % flex life improvement compared to the standard WRM product and , even with large application strains of 11 %, greater than 60,000 flex cycles have been recorded in laboratory testing .”
The new materials have been tested at temperatures up to 80 ° C over extended periods and offer an 800 % improvement in hydrolytic stability compared with conventional polyurethane chemistries , according to LANXESS . This enables the repair of pipe lines , pump liners , impellers , rotors and other applications where slurry temperatures are above normal ambient conditions .
WRM 80 T Premium and the WRM 65 T Premium are available in 0.75 kg and 1.5 kg kits .
The WRM 65 T Premium is specifically designed to have ‘ rubber like ’ properties and is , therefore , suitable for the repair of rubber parts . The WRM 80T Premium material is designed for polyurethane and metal repairs .
The WRM range of products is commonly used in the repair of conveyor belts to rebuild worn areas and fill voids from mechanical damage . The WRM 65T Premium grade has a modulus and hardness close to the rubber belt itself and can be quickly applied , providing a product with high flex life and abrasion resistance .
The high wear / tear resistance and noise absorption properties of the WRM Premium systems makes them a logical choice for the repair and lining of vibratory bowl feeders typically made from metals .
WRM has also proven to be the material of choice for the repair of spiral separators , LANXESS says . The repaired spirals have the same wear life as new parts , resulting in considerable cost savings , according to the company . IM
JANUARY 2021 | International Mining 53