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Using Scanalyse Technology forCrushers and Grinding Mills

Mining Magazine CongressDate; 10 November 2010

steve.hall@scanalyse.com.au

Mining Magazine CongressDate; 10 November 2010

steve.hall@scanalyse.com.au

mailto:steve.hall@scanalyse.com.aumailto:steve.hall@scanalyse.com.aumailto:steve.hall@scanalyse.com.au

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WagerupWorsleyKwinanaKanowna

St IvesKCGMBlack SwanLeinster

Kimberley NickelTanamiMacarthur River

CenturyErnest HenryCannington

Olympic DamOneSteel

NorthparkesCadia

Batu HijauFreeportOk Tedi

Morobe-JV

Macraes

Red Dog

Highland Valley

KennecottRobinson

YanacochaAntamina

Mantos BlancosMantos de OroCollahuasiEscondidaCandelariaLos PelambresLos BroncesTeniente

ParactKinross

Lumwana

ModikwaWaterval

Peasquito

Scanned Mill Locations

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MillMapper

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Data Capture

Traditional

Scanalyse

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Raw Scan Data Quality

5Each pixel has X, Y, Z (3-D) coordinate

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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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Liner Profiles; Cross-sectional and Longitudinal

Data from 3D model

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Multiple Scans

enable sequentialWear Monitoring

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Wear Tracking

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New 1 month

2 months 3 months

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How do we process the data?THE SCAN CAPTURES ALLINTERNAL SURFACES

TRANSVERSESECTIONAL PROFILESARE ANALYSED AT

100mm INTERVALS TOPROVIDE HIGHLYDETAILED THICKNESSDATA

THE COLOUR LEGEND FORTHICKNESS ALLOWS VISUALINTERPRETATION OF THE3D MODEL

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Profile Location

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Wear Curves

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Wear Curves

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Reline Forecasting

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Scan Nov 5, 2007Reline 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

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30% extra life in SAG

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Extend liner life

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4 fold increase for inner discharge liners

over 3 years, saving $500,000

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Extended Shutdown periodswith security due to improved

Condition Monitoring and metrics

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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

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USA Site

Liner weight reduced by 14,000 lbs

Liner Life maintained

After 6 months MillMapper service

has paid for itself several timesover

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Increase Production

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Potencia & Tonelaje - Yanacocha Abril/Noviembre 2008

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

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

Tiempo [das]

Mill Power TonelajePolinmica (Tonelaje) Polinmica (Mill Power)

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Increase Production

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Increase Production

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Chilean Site

New liner design modified tomatch partly worn shape

Production increase ~ 3%

MillMapper used to ensureliner life maintained

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Ball Size Distribution

New MillMapperTMFunctionality

3D Scan Photograph3D Scan Photograph

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Ball Size Distribution

New MillMapperTMFunctionality

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

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Ball Size Distribution

New MillMapperTMFunctionality

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Grate Open Area

New MillMapperTMFunctionality

Output Features;

Dimensioning and tracking of Open Area

Hole location

Broken grate sections

Hole % and location pegged

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MillMapper Deliverables

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Typical Service:

Complete 3D File

Wear Report

Flag Report

MRA

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CrusherMapper

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Laser scanningData collection of several million 3D pointmeasurements using a Laser scanner

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Laser ScanningSample 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 Worn Concaves

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Thickness new Concaves

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CrusherMapper 3D ViewerAsymmetric Wear (unwrapped)

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Thickness 16-Jun-2009Thickness 24-Nov-2008

Rockbreaker

Grizzly

Rockbreaker

Grizzly

Rockbreaker

Grizzly3D Thickness change / wear

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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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Dam ag ed zone found in Ma ntle minimum thic kness of

32 mm identified using C rusherMapp er3D

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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

48 CM and Lube Forum, Sydney, October 2010

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Concave / Mantle Condition Tracking

Average

longitudinalprofiletracking

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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 detailData 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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