Spotlight Feature Articles WEAR PARTS & GET | Page 7

WEAR PARTS & GET
mining can affect both current and downstream
operations. At ME Elecmetal, we understand that
every decision made is absolutely critical. Before
proposing changes to our customers, we run a
series of simulations and tests, so we can be
confident that the solutions we are developing
will minimise any risks or adverse effects. ME
Elecmetal’s technical support and training goes
above and beyond standard services offered by
other suppliers. These services include DEM and
FEM simulation services, 3D laser scanning for
wear analysis, reline optimisation, continuous
improvement programs and grinding circuit
optimisation.”
Finally, VAES (Value-Added Engineering
Services) is ME Elecmetal’s business philosophy.
This benefits-based sales philosophy is focused
on providing customers with comprehensive,
value-added solutions for ore processing which
positively impact six key operational areas:
Increased production; Greater equipment
availability; Cost-effective solutions; Environmental
and health protection; Safety (handling,
management and storage); and Training.
“As part of VAES, we record the tangible
benefits of every project in a report provided to
our customers. Through the VAES program, ME
Elecmetal is able to help customers optimise
processes, extend the lifespan of wear parts,
reduce operational risks and increase
profitability Earning the trust of our customers is
our priority. We achieve this through proposing
technical solutions that offer substantial benefits
with minimal risks. At ME Elecmetal, we accept
the responsibility of growing our credibility with
the customer by integrating world class
complementary products and services.”
Metso wear solution reduces
Kolomela downtime
Kolomela produces over 13 Mt/y of iron ore, and
is one of Anglo American’s largest operations in
South Africa. Anglo American is implementing a
broad and progressive programme of change that
is designed to be game-changing for the
industry. The role of innovation and digitalisation
is key to delivering sustainable safe production.
In mineral processing, crusher efficiency can
be compromised over time, affecting production
time and, most importantly, the safety of
employees. A major factor affecting crusher
efficiency is the amount of downtime. The longer
it takes to replace the wear parts inside the
chamber of a primary gyratory crusher during a
maintenance shutdown, the less uptime and
thus, less production. By reducing the number of
lifts, the replacement can be done much faster
and safer.
Kolomela approached Metso’s expert team to
help them reduce the average downtime the
operation encounters when replacing concave
liners of their SG60-110 crusher. “When the mine
approached us with a request to help them
speed up the process of changing the concave
liners on the primary gyratory on site, they asked
us to replicate the methodology that we once
used at one of Anglo American’s major copper
mines in South America, Los Bronces, which
included the use of special tooling such as
carousels and removal trays to remove the liners.
Following the review of the Los Bronces system,
we identified that we used different parts and
installation methods not suitable for Kolomela’s
operating model,” said Metso’s Regional and
Technical Support Manager Crusher Wears,
Andrew Stones.
By reducing the number of lifts, the
replacement can be done much faster and safer.
Metso’s team looked at an alternative innovative
solution not only for different fixing arrangement
on the carousels, but they also changed the
parts. Instead of the mine having six rows of
concaves to install, Metso reduced the rows to
Kolomela mine has reduced liner replacement
downtime and improved safety using Metso’s
concave carousel and removal trays system
downtime was not the only value add that was
provided, the mine also reduced by 95% the
injury exposure rate. Unlike the previous system
that the mine used which required people to be
in the crusher when lowering each concave,
Metso’s innovative carousel system provided
optimised operating labour and safer
installations. It is not dependent on human
interaction.”
“At Anglo American, we are unconditional
about the safety of our colleagues. When the
Metso team highlighted the safety element that
the carousel methodology brings, it was indeed
an added benefit and advantage. We understood,
at that point, that Metso will also prioritise the
safety and well-being of all individuals. There is
no price on safety" said Kolomela’s Section
Manager Engineering, Pieter Malan.
“When the Metso team highlighted the safety
element that the carousel methodology brings, it
was indeed an added benefit and advantage. We
understood, at that point, that Metso will also
prioritise the safety and well-being of all
four. This minimised the installation time. In
addition to this, the team supplied Kolomela with
removal trays - which enable a faster removal of individuals."
“Previously, the Kolomela mine used 288 lifts
to remove and install each concave liner; a
process that has been identified as potentially
hazardous work for the liner replacement team.
Our new concave carousel concept reduced the
the worn segments - as well as with modified
attachments to help lift and install the carousels.
Metso’s solution has halved the downtime
required for a concave liner change. “Reduced lifts to 16, substantially improving both uptime
and safety. The carousel allowed an entire tier of
new concave segments to be lifted in place at
once” added Metso’s Vice President Mining,
SEPTEMBER 2019 | International Mining