IM 2021 June 21 | Page 62

HEAVY ENGINEERING & WEAR PARTS

Made to measure

As smart design and engineering is bolstered by safe and quick maintenance , plus new and intuitive digital tools for monitoring , process plant and mine site equipment is tending to run for longer . Dan Gleeson peers into the heavy engineering and wear parts space to find out how these market segments are aiding such operational longevity

The mining industry is more readily using the oodles of data at its disposal to provide real-time results in the process plant and mine site .

Having picked up on just how important realtime orebody knowledge is to mineral processing outcomes , the industry is now using timely equipment health data from the process plant and mine site to ensure it captures all available productivity wins .
Where finite element analysis and discrete element modelling in the design phase has allowed OEMs and consumers the ability to gauge how components and wear parts will react to operating on site or in the process flowsheet when fed with certain material , a similar modelling philosophy in the operational phase is now reducing downtime , increasing wear part life and improving safety .
Obtaining real-time knowledge of what is going on inside the mill is within the scope of Magotteaux ’ s MagoSense solution .
Leveraging the company ’ s significant experience in designing and supplying cast and forged , low and high chromium grinding media and tailored mill liners , Magotteaux , together with its Germany-based partner , KIMA Process Control , has come up with a digital tool that lets operators “ see ” what is happening inside their operating mill .
Historically , impact measurements in mills were based on the human ear or relied on the skill and experience of the person who calibrated the measurement system . Both methods tended to be subjective and reactive , leading to unwanted and – potentially – unnecessary downtime .
MagoSense uses vibration and shell-bending sensors , as well as digital signal processing technology , to provide information about what is happening at each of the 360 degrees of the mill , Magotteaux claims .
Providing the total volumetric filling and ball impact information , MagoSense allows the operators to closely follow mill operation and seek optimal working conditions that directly lead to improved performance , the company says .
All technical aspects of MagoSense , such as wireless data transmission , power supply and overall system robustness , have been proven and widely adopted by industry leaders in the cement industry , yet the tool is designed specifically for the mining industry .
“ Primarily developed for use on SAG mills , it can operate on any type of tumbling mills and is adapted to the harsh mining environment ,” Magotteaux said .
As the company explained , SAG mill operation is “ sensitive ” to changes in ore quality ( hardness and size ). Changes in the feed can quickly result in a build-up , or loss , of rocks inside the mill . Both situations result in undesirable conditions for milling .
MagoSense uses vibration and shell-bending sensors , as well as digital signal processing technology , to provide information about what is happening at each of the 360 degrees of the mill , Magotteaux claims
“ MagoSense will prevent you running blind by gathering information in order to optimise the working conditions of the mill ,” Magotteaux said .
Two of the core unique aspects that come with MagoSense are : n All measuring devices are installed directly to the outside of the mill shell . MagoSense does not suffer from sound interference like other off-mill sensors do ; and n The energy required to power all the electronics is supplied by a pendulum-driven electrical generator , meaning no batteries are required . MagoSense helps control the mill fill level to avoid mill overloading and allow better control of mill grind-outs , according to the company . It also minimises liner damage and wear by helping reduce the occurrence of ball impacts on liners .
Milling efficiency can also be boosted by helping the mill operator decide on the best grinding strategy to maintain the optimal power and load-charge conditions .
And , of course , MagoSense helps reduce unexpected mill stops due to any type of grinding issue , positively impacting safety and productivity .
58 International Mining | JUNE 2021