Monitoring Primary Crusher Performance (Nkomati Mine)
Requirement: Enable real-time quantification of operating and equipment conditions to improve overall performance.
Approach: Optimum operating conditions were derived – optimum conditions are defined by factors such as throughput, open side setting (size distribution affects the milling section performance), and equipment constraints/ life e.g. motor current, idle time (excessive long idle time reduces lubrication effectiveness on the eccentric bearing).
Solution: Application specific benchmarks were derived describing optimum production and equipment performance. Two ore types are processed on this gyratory crusher and benchmarks were derived for each ore type.
• Percentage compliance with benchmark definitions illustrates the plant’s capability to realize strategic objectives (evaluating historical data).
• Real-time quantification of operational performance enables pro-active management of conditions that may result in sub-optimal performance. Monitoring provides, for example, early warning of deteriorating performance within mining (e.g. mining capacity issues, performance variance between shifts).
• Early warning of deteriorating equipment performance. Models have previous provided early warning (>20 days) of abnormal behaviour on the 3.5MW electrical motor.
Projects are executed following the MESA International endorsed Time-in-State methodology.
The following list references applications:
Milling Circuit - Monitoring
Real-time monitoring of milling circuits to detect deviation from optimum state. Observations triggered further investigation that resulted in >7% increase in throughput.
Utilized analytics to derive an optimum recipe (reagent dosing rate, mass pull, cell level and concentrate grade). Results contributed to >2% increase in recovery.
Provide real-time quantification of thickener condition by interpreting rake torque, underflow density and flow.
Secondary Crushing Circuit Performance
Evaluation of a complete crushing circuit to identify root causes for sub-optimal performance. Used information to determine the viability of a project to increase decoupling capacity.
Execute an assessment to determine an operating plant’s capability to comply with the business plan. Results assisted in generating a realistic stretch target. The latter contributed toward buy-in from operational personnel.
A structured methodology and supporting technology are used to integrate operational personnel’s knowledge and experience with information extracted from plant data. A platform is established that increases overall efficiency and effectiveness – this can either delay the need for capital investment and/or reprioritize initiatives. Services are delivered by a highly qualified engineering team. Projects are characterized by a high internal rate of return and low risk. Time-in-State delivers insight into issues and delivers answers to difficult questions through effective use of data, analytics, technology ,and people.