MINE MAINTENANCE
Metso Outotec can carry out some predictive maintenance diagnosis from its Performance Centers in Chile , Finland and China , where it has data channels and equipment experts analysing the data
mine in Finland back in 2019 provides a good example here .
When the mine acquired a new MF Series™ screen in May of that year , it incorporated Metrics to bolster its maintenance efforts at the front end of the flowsheet . Such a solution allowed the company to assess any issues ahead of failures and deploy maintenance personnel to site only when needed .
Soon after installation of the screen and Metrics platform , the operators at Kevitsa and the Metso Outotec team monitoring the screen ’ s performance noticed there was something wrong with its running speed . With this data – and through collaboration with Metso Outotec personnel – the root cause was determined to be two broken V belts . In the end , this predictive maintenance solution aided the operation in minimising downtime at a time when the company was expanding plant throughput to 9.5 Mt / y .
To date , it is crushers that have benefitted most from Metrics “ predictive ” capabilities , according to Koivunen , but that could soon change .
“ We are now offering the Metrics solution on a commercial basis on horizontal mills ,” he said .
“ Given mills are such a critical piece of the flowsheet , we expect to see much interest in monitoring this process .”
And the company is also developing predictive maintenance capabilities related to crusher wear parts .
“ We already use online data feeds for crusher cavity optimisation ,” Koivunen said , explaining :
“ By using online data to see how the equipment is behaving before a new set of liners is fitted and comparing this with data after new liners are installed , we can provide some predictive capabilities for liner changes .”
The company is periodically updating the Metrics offering to strengthen existing solutions with more accurate algorithms and troubleshooting procedures , as well as capabilities for new equipment within the flowsheet .
And going forward Koivunen sees Metrics playing a bigger role in the company ’ s Life Cycle Services ( LCS ) agreements .
“ The differentiated equipment offering from Metso Outotec , plus the ability to integrate Metrics into these LCS agreements , is another important aspect ,” he said . “ Having the understanding of the baseline equipment performance and the data on real-time performance gives us more flexibility with performance-type of contracts ,” he said . “ The same data is used by us and the customer , improving the transparency when it comes to providing actual results .”
Remote monitoring for all
Mikko Tepponen , Chief Digital Officer of FLSmidth , is of the opinion that customers should be able to leverage some remote condition monitoring data from all mineral processing equipment .
In the last year-or-so , he and his team have focused on how it can embed this philosophy across the company ’ s product offering .
“ How we have structured that is very clear : we look at all the possible failure modes a single piece of equipment might have and then assess which of them can be detected from the existing dataset ,” he told IM . “ In these instances , we ’ re looking at what data can be captured immediately to provide instant value for customers .”
Such ‘ instant value ’ could be provided by FLSmidth through analysis of flotation cell data outputs , for instance , where the company ’ s expert insight and “ deterministic approach ” to condition monitoring could help mining companies predict failures before they occur .
Where such data is not available for the equipment in question , there is potential to bolt on sensors from third parties – such as vibration sensors – or FLSmidth ’ s own
sensor solutions – such as its LoadIQ™ smart sensor technology for SAG mills – to generate it .
These digital solutions are reinforced by “ dayto-day ” remote troubleshooting support from FLSmidth technicians , which has increasingly leveraged ‘ smart ’ glasses or other technology to tap into the mine site maintenance team or local aftermarket operative in question and get around travel or site restrictions , Tepponen explained . “ For us , the two key elements across the entire flowsheet are the need to help customers predict failures before they happen and then offer that day-to-day support in case of any issues ,” he said .
FLSmidth is not looking to provide the data “ platform ” for customers when it comes to remote equipment monitoring but wants to create and distribute the apps and solutions that can be incorporated into a mine site ’ s existing digital architecture .
“ At FLSmidth , we don ’ t think of ourselves as a platform provider – everyone has a digital strategy , everyone is collecting data and the majority have already selected a platform provider ,” Tepponen said . “ Yet , the data feeds from our flotation cells , or mills , for example , come with a standardised interface and an API ready to connect to a PLC of the customer ’ s choosing . We can then – via this PLC – provide you with the recommendations and actions to confront any issues with our apps .”
The company ’ s ‘ app store ’ includes SiteConnect™ , which delivers insights on the go with on-demand equipment and plant performance and health data . This leverages off a management information system , called ECS / PlantDataManagement , which integrates all process and quality information islands , making critical real-time plant data available to operational , management and executive personnel .
When combined with solutions such as LoadIQ , SmartCyclone™ and the Raptor cone crusher “ R ” line , these deliver connected data and connected employees , allowing for
FLSmidth ’ s remote performance centres leverage the global tools , capabilities and expertise of the wider group
38 International Mining | JANUARY 2022