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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 [email protected]
www.maptek.com
Elton du Plessis, Regional Manager – Laser Imaging, [email protected]