Instant data, instant decisions: Unlocking a new frontier in mining maintenance
The mining industry is acutely aware of the looming challenges surrounding increased demand for critical minerals. Notably, there is a significant gap between prospective supply and demand for copper, as the International Energy Agency (IEA)¹ forecasts that mine supply from announced projects meets only 70% of copper requirements. With the energy transition continuing to gain momentum, mining organisations around the world are under mounting pressure to increase production by approximately 20-30% within the next seven years. This is an undertaking comparable to establishing a production capacity on the same level as Chile, the world’s largest copper producer. Declining ore grades further exacerbates this challenge; copper mining companies are processing ores with 1 ton of copper for every 100 tons of rock, at best.
In the face of these evolving challenges, mining organisations need reliable, efficient and scalable grinding technology solutions. Gearless mill drives (GMDs) have become a critical component in mining operations due to their enhanced operational reliability. The unique GMD concept eliminates the need for conventional mill drive components, such as ring-gears, pinions, gearboxes and couplings, which reduce mill availability and require regular and accurate maintenance to minimise the unavoidable additional efficiency losses they cause.”
However, effective and timely maintenance is key to maximising the efficiency and longevity of these components. In a process such as grinding, where every operational minute counts, unplanned downtime has a significant impact on the business, as it can damage profitability and productivity.
Getting to know Gearless Mill Drives (GMDs)
Gearless Mill Drives (GMDs) are the backbone of grinding operations in the mining sector. Unlike traditional systems, where various mechanical components like ring gears, pinions and gearboxes are required, GMDs integrate the rotor poles directly onto the mill. This design transforms the mill into the rotor of the gearless motor, streamlining the system by removing the need for additional mechanical parts. As a result, the reliability and efficiency of the operation are significantly enhanced.
GMDs deliver several key benefits compared to other mill drive options. They can achieve higher power levels while simultaneously lowering overall energy consumption. Moreover, the streamlined mechanical design and reduced component count, combined with greater power output, allow for a smaller overall footprint. This compact design is particularly beneficial in remote or environmentally sensitive areas, where efficient land use and minimising environmental impact are critical.
The vital role of remote diagnostics
Traditionally, troubleshooting for grinding technology has required the on-site presence of an engineer or a direct remote access to the plant to identify the source of problems. This approach can be challenging and inefficient, as it relies on the right person being available at the right time.
Remote diagnostics, combined with on-the-ground maintenance, are vital in an effective service approach. Real-time monitoring and diagnostics of GMD systems are facilitated by digital tools and IoT devices, offering valuable insights into equipment performance and health. The predictive software calculates potential failures through detailed analysis of historical and immediate data on the GMD’s electrical, mechanical and thermal parameters. This allows for more precise and effective maintenance strategies that adapt to changing conditions and requirements.
A revolutionised approach to diagnosis and troubleshooting
ABB’s Ability™ Predictive Maintenance for Grinding (PMG) monitors critical assets’ health against pre-defined thresholds, notifying operators of detected anomalies. It provides easy access to GMD system values and allows visualisation of performance, considering past activity and instant data, and assesses future maintenance requirements. Ongoing health assessments also potentially allow preventive actions before failures occur. When paired with the Grinding Connect mobile app (available for iOS and Android), users can expect live notifications for precise fleet management and monitoring.
As demand for GMDs increases, ABB has enhanced its PMG platform with an all-new solution, designed to make the troubleshooting and diagnostics process faster and more efficient than ever before. The latest cloud-based application named Trendex™ will give users of the platform visibility of event data in high resolution 3 seconds before and 1.3 seconds after the event. Trendex works by automatically pushing event files to the cloud and linking event data with the transient records, providing users with near-instant access to operational data from any internet-connected device. It also delivers improved diagnostic and visualisation features to help engineers quickly restore production.
Data is central to corrective, preventive, predictive and prescriptive maintenance concepts. However, data is only the beginning as it needs to be transformed into meaningful information and visualised in the right way. The ability to gather and analyse data offers precise visibility into the health of GMD systems. This visibility benefits operators by enabling them to plan or defer maintenance tasks confidently based on condition reports and shifting priorities.
Eliminating the need for a direct remote connection while granting almost immediate access to the event-related signals in high resolution results in significantly faster response time in case of a trip. Trendex will empower users, regardless of location as long as they have an internet connection, with real-time data to identify faults when they happen, pinpoint the root cause quickly, and swiftly return operations to full production.
Trendex is now available for all users of the PMG platform and ABB is working closely with customers to ensure they get the most out of this innovative new tool.
¹ International Energy Agency, Global Critical Minerals Outlook 2024, May 2024