MINE MAINTENANCE
This engine uses advanced statistical techniques , AI and machine-learning algorithms , which can be leveraged to create and deploy digital twins using both long-term and short-term historical data from a SAG mill and other mineral processing units . It uses these data to train and develop data-driven models capable of predicting future values of key variables in real time .
Using techniques like vibration analyses , failures can typically be predicted between days and even weeks in advance , according to Molycop , giving operators opportunity to plan for replacement of critical parts before failure .
“ There is a massive potential for improvement in the industry to complement scheduled maintenance with predictive maintenance ,” the company said . “ Having live relevant data like vibration , wear measurements , ultrasound and image analyses techniques that all work hand in hand with data analytics , AI and machinelearning techniques can allow the delivery of predictive maintenance outcomes as the next frontier in mine maintenance advances .”
Additionally , the Digital Engine includes a built-in optimiser that allows for intelligent finetuning of performance and enhances overall efficiency , according to Molycop .
The Digital Engine has been successfully applied to predict the performance of the SAG mill at a mineral processing plant in Western Australia where it demonstrated a high level of accuracy in predicting and detecting potential changes and variations in SAG power draw and
SAG pebble discharge rate , according to the company .
“ It was able to achieve this by consistently providing predictions with errors of less than 2 % and 5 % in several consecutive steps , respectively ,” Molycop explained . “ In instances where an out-of-normal state was detected , the digital twin promptly triggered an alarm to alert the operator .”
Additionally , it provided information on the variables that contributed the most to the observation of the out-of-normal state , with this feedback empowering the operator to take informed actions and make necessary adjustments to bring the SAG mill back to the desired operating state .
“ The results obtained from the predictive analytics indicate that the high variability of the SAG milling process , particularly fluctuations in feed characteristics , had minimal impact on prediction accuracy ,” Molycop said . “ This is attributed to the use of short-term data , specifically a 48-hour interval , to train a new model at each iteration .”
A beta version of this product is already available for clients to trial when implemented in combination with MillSlicer VIP , according to Molycop .
Metso putting ‘ skin in the game ’
Metso ’ s Rashmi Kasat believes the ability to integrate the company ’ s digital solutions into its life cycle services ( LCS ) contracts is allowing the
OEM to put more “ skin in the game ” from a maintenance risk and reward perspective .
Kasat , who leads digital transformation within the Metso mining segment ’ s Digital unit , as Vice President , Equipment Performance , says this combination provides customers with peace of mind , allowing them to focus on their core business and leave the maintenance and operation of equipment to Metso experts .
The company is currently able to offer such a service across all its digitally enabled products , including on crushers , mills , filters , screens , pumps , and Courier and PSI analysers . This is enabled through its Metrics Monitoring service , overseen by Metso Performance Centers in Finland , Chile and China .
Such oversight is set to expand across thickeners , flotation cells and potentially also hydrometallurgical equipment , Kasat said , allowing the company to monitor equipment across the whole flowsheet .
The business case for employing these solutions alongside such service contracts has not changed in the five-and-a-half years since the Metrics platform was launched , however the trends being tracked by mining companies has altered in line with an accelerated sustainability drive .
“ Clients want to secure the availability and reliability of the equipment and they want to take proactive actions to prevent unplanned downtime and expensive , irreparable damage to the equipment ,” Kasat explained . “ Beyond keeping
Why it ‘ pays ’ to be strategic with mining tyre service work
Data-driven insights are providing new possibilities to optimise the servicing of mining tyres , cutting downtime and costs , while improving safety , Mark Goode , Director for Business Insights at Kal Tire ’ s Mining Tire Group , says .
Traditionally , mining tyre service strategies have centred on maximising tyre life , speaking not only to the cost of tyres and the desire for each operation to get the most from its assets , but also the way in which the tyre industry is structured .
Goode explains : “ Tyre manufacturers usually base the performance of their products ( and compare them to competitors ) on a cost-per-hour basis , and so this is a metric that mines and tyre distributors have tended to focus on .”
In recent years , a degree of disintermediation in tyre supply has led many mines to purchase tyres directly from manufacturers . This has shifted the dynamics and meant some tyre distributors are placing a greater emphasis on the service elements of their businesses .
“ This is a good thing for mining companies , because it means they can ( if they wish ) examine and optimise their tyre service strategy independent from their supply strategy ,” Goode said . “ Although the two will always be inherently linked , optimising them separately provides potential opportunities to redefine success in each area , widening the scope to better reflect each site ’ s priorities and objectives .”
While tyre service providers can have a significant impact on tyre performance , there are other factors that may play a more fundamental part in determining ultimate tyre performance . Operational decisions , for instance , in haul road maintenance or pit design , the experience of truck operators , climatic conditions and the choice and quality of tyre , also play their part . Likewise , commodity cycles have a big influence .
Whatever the focus from a tyre management aspect , there are certain activities that service providers typically incorporate , such as tyre rotations . Additionally , tyre performance can be extended through repairs and re-treading . All these activities require downtime , and that comes at a cost . Goode says it is only in the past five years that tyre service providers have developed tools to provide greater visibility on the cost of downtime associated with tyre servicing . New generation tyre management software linked to the mine plan means that it is now possible to accurately calculate the cost of downtime associated with tyre service activities .
“ The introduction of Kal Tire ’ s Tire & Operations Management System ( TOMS ), in 2016 , means that we can now tell mines how much it costs them in availability every year to service their tyres ,” Goode said .
That information is powerful in identifying opportunities for improvements and , when combined with aggregated and anonymised TOMS datasets , offers an opportunity to benchmark performance between sites the company services . This can see Kal Tire work with several customers to prove how effective tyre service optimisation can potentially be .
“ It ’ s not usually possible to maximise both tyre performance and utilisation ; one will nearly always come at the expense of the other ,” Goode says . “ However , using the management systems and insights available today , mines can strike an acceptable balance between the two , which allows them to meet both their safety and financial goals .”
36 International Mining | JANUARY 2024