Using Scanalyse Technology for Crushers and Grinding Mills

Mining Magazine Congress Mining Magazine Congress

Date; 10 November 2010 Date; 10 November 2010 steve.hall@scanalyse.com.au steve.hall@scanalyse.com.au

Red Dog

Highland Valley Kennecot t Robinson Peasquit o Yanacocha Antamina

Mantos Blancos Mantos de Oro Collahuasi Escondida Candelaria Los Pelambres Los Bronces Teniente

Batu Hijau Freeport Ok Tedi Morobe-JV

Lumwana

Macraes

Paract Kinross

Modikwa Waterval

Wagerup Worsley Kwinana Kanowna St Ives KCGM Black Swan Leinster

Kimberley Nickel Tanami Macarthur River Century Ernest Henry Cannington

Olympic Dam OneSteel Northparkes Cadia

Scanned Mill Locations

MillMapper

Data Capture

Traditional

Scanalyse
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Raw Scan Data Quality

Each pixel has X, Y, Z (3-D) coordinate

Raw Data

Thickness Model

The software produces X, Y, Z, t (4-D) model

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Typical 3D Model Views

Feed

Shell
Colours indicate Thickness
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Data from 3D model

Liner Profiles; Cross-sectional and Longitudinal

Multiple Scans enable sequential Wear Monitoring

Wear Tracking

New

1 month

2 months

3 months
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How do we process the data?

THE SCAN CAPTURES ALL INTERNAL SURFACES TRANSVERSE SECTIONAL PROFILES ARE ANALYSED AT 100mm INTERVALS TO PROVIDE HIGHLY DETAILED THICKNESS DATA

THE COLOUR LEGEND FOR THICKNESS ALLOWS VISUAL INTERPRETATION OF THE 3D MODEL

Profile Location

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Wear Curves

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Wear Curves

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Reline Forecasting
Scan Nov 5, 2007 Reline on Feb 5, 2008

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Liner Profiles

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Liner Design Optimisation

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Ball Charge Measured

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MillMapper Benefits/ Case Studies

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Avoid Catastrophic Failure

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Avoid Catastrophic Failures

Century Zinc

SE Asian Site

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Compare Liner Performance

Shell Liners A & B

Alternative Alloys or Different Geometries
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Extend liner life

30% extra life in SAG

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Extend liner life

4 fold increase for inner discharge liners over 3 years, saving $500,000

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Extended Shutdown periods with security due to improved Condition Monitoring and metrics
OZ Minerals Century 12 weeks to 16 weeks ERA Ranger 12 months to 16 months Century saves one complete Shutdown per year
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Reduce Liner Weight

USA Site Liner weight reduced by 14,000 lbs Liner Life maintained

After 6 months MillMapper service has paid for itself several times over

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Increase Production
Potencia & Tonelaje - Yanacocha Abril/Noviembre 2008
20000 Mill Power Polinmica (Tonelaje) Tonelaje Polinmica (Mill Power) 18000

16000

14000

12000

10000

8000

6000

4000

2000

0
22-02-08 12-04-08 01-06-08 21-07-08 09-09-08 29-10-08 18-12-08

Tiempo [das]

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Increase Production

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Increase Production
Chilean Site New liner design modified to match partly worn shape Production increase ~ 3%

MillMapper used to ensure liner life maintained

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New MillMapperTM Functionality Ball Size Distribution

3D Scan Photograph

New MillMapperTM Functionality Ball Size Distribution

Output Features Version 1 (release late-2010) Dimensioning of ball size distribution Tracking of ball size distribution Future Versions : Identification and separation of balls and ore SAG / AG mill ore sizing

New MillMapperTM Functionality Ball Size Distribution

New MillMapperTM Functionality Grate Open Area

Output Features; Dimensioning and tracking of Open Area Hole location Broken grate sections Hole % and location pegged

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MillMapper Deliverables
Typical Service: Complete 3D File Wear Report Flag Report MRA
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CrusherMapper

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Laser scanning
Data collection of several million 3D point measurements using a Laser scanner

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Laser Scanning
Sample scan cloud

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CrusherMapper 3D Viewer
Determination of concave/mantle liner thickness

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CrusherMapper 3D Viewer
CM assessment in software viewers

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CrusherMapper 3D Viewer
Thickness new Concaves Thickness Worn Concaves

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CrusherMapper 3D Viewer
Asymmetric Wear (unwrapped)

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Rockbreaker

3D Thickness change / wear

Thickness 24-Nov-2008

Grizzly

Thickness 16-Jun-2009

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CrusherMapper 3D Viewer
Localized liner fractures / failures

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CrusherMapper 3D Viewer
Localized liner fractures / failures

Damaged zone found in Mantle minimum thickness of 32 mm identified using CrusherMapper3D

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CrusherMapper 3D Viewer
Localized liner fractures / failures

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CrusherMapper 3D Viewer
Localized liner fractures / failures

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CrusherMapper 3D Viewer
Oversize crusher product production caused by asymmetrically wearing crushing zone

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CM and Lube Forum, Sydney, October 2010

Concave / Mantle Condition Tracking

Average longitudinal profile tracking

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CrusherMapper Benefits
Data collection can be completed remotely, thereby : Enabling completion without any additional downtime Eliminating all safety risks to condition monitoring personnel Eliminating the need for confined space isolation overheads Data covers the entire Concave liner area at very high detail Data covers the entire Mantle liner area at very high detail Data is accurate, repeatable and reliable Data collection on Mantles is possible in situ
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CrusherMapper Benefits
Maximum wear location is automatically located and quantified Wear tracking is tonnage based Tonnage based reline forecast is automatically calculated Liner failures can be detected in situ A multitude of profile outputs can be used for liner redesign

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Thank You

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