monitoring wear rates and patterns in crushers - thank · pdf filemonitoring wear rates and...

Monitoring wear rates and patterns in crushersPeter Johnson, Elton du Plessis, Maptek

I-Site laser scanner + Vulcan modelling software

cost effective safe solution predict downtime optimise downstream processes

Controlling fragmentation size

Safety and timeProduction must stop when the crusher is shut down for measurements.Loss of revenue estimated at US$200,000 p/hour.Traditional manual measurements typically take 3 hours…

3 hours @ $200,000 per hourx every 10 weeks =

3 million dollars per annum in lost production

The Solution

Point cloud showing four scan datasets registered to represent internal surfaces of crusher

Section view of modelled data showing four levels of the crusher model

Radial distribution of wear (in metres) at the four levels in the crusher

Arrangement of crusher segments and loading area

Horizontal section through crusher surface showing uneven wear around liner edges.

Distance histogram

Modelled laser scan data showing surface detail on worn liners

Digital data = more informed decisions

Reduce downtime Increase revenue

Conclusions Time to perform measurement reduced by 80%

Several safety risks were eliminated

Improved efficiency and workflow

Significant benefits

Monitoring wear rates and patterns in crushers

Peter Johnson, General Manager Australasiapeter.johnson@maptek.com.au

www.maptek.com

Elton du Plessis, Regional Manager – Laser Imaging, AfricaElton.duplessis@maptek.co.za