Tag Archives: mill relining

Bradken out to improve safety, duration of mill relining process with MillSafe Solutions

Comminution of minerals, Equipment maintenance, Mining consumables, Mining equipment, Mining services, , ,

Bradken says it is addressing both the associated risks and duration of the relining process for AG, SAG and ball mills through the development of a new technology platform, MillSafe® Solutions.

Showcased at the recent MINExpo International 2024, in Las Vegas, MillSafe Solutions are expected to improve the efficiency of the mill relining process and make the process safer, Bradken says.

MillSafe Solutions incorporate innovative product development and installation processes to achieve this, leveraging technology to enhance its designs and remove people from hazardous zones during mill relining, the company explains.

Bradken says it continues to work with partners to develop advanced universal worn liner removal and installation solutions to improve reline safety, being a leader in the design, manufacture and supply of mill liners for primary and secondary applications in the global mineral processing industry.

The company offers customers complete wear liner solutions for mills that increase performance, safety, equipment availability and lower maintenance costs, it claims.

The MillSafe Solutions incorporate:

  • MillSafe Combined Corner Liners;
  • MillSafe Liner Location Stripes;
  • MillSafe Backing; and
  • MillSafe Bolting

Bradken’s Combined Corner Liner design improves reline safety, and significantly reduces reline times, part inventory and liner weight, according to the company. The MillSafe Liner Location Stripes provide visual guidance to deliver a safer and more efficient liner install.

MillSafe Backing is a replacement for grinding mill rubber sheeting. Designed to remove costly maintenance delays to repair damaged rubber sheeting on grinding mills, it provides a safer relining environment, according to Bradken.

The MillSafe Bolting System, meanwhile, is a safer and more efficient solution for liner installation and removal, as you can install liners by bolting them from outside the grinding mill, therefore removing people from hazardous zones within your grinding mill.

Mill relining system major RME celebrates 20 years in South America

Automation, Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , , ,

OEM RUSSELL MINERAL EQUIPMENT (RME) is celebrating its 20th anniversary in South America, highlighting its ongoing deep connection and commitment to the region.

RME says it is seizing the milestone to express its gratitude to the team members, customers and suppliers who made RME the region’s most trusted OEM of mill relining technologies.

RME’s history in South America dates to 1996 with the export of the first RUSSELL Mill Relining Machine (MRM) to the region. With a steady stream of technology installations in the years that followed, RME established a direct presence in the region in 2004 to better serve its growing customer base.

Today, RME has five dedicated RME Regional Service Centres in Latin America and its equipment operates on 77 Latin American mine sites across Argentina, Bolivia, Brazil, Chile, Colombia, Dominican Republic, Mexico, Panama and Peru.

RME Founder, Executive Chairman and Chief Engineer, Dr John Russell, described South America as a cornerstone of RME’s operations.

Dr Russell said: “From the arrival of the first RUSSELL MRM on the continent in 1996, the opening of our regional service centre in Chile in 2004, and the opening of offices in Peru and Brazil in 2021 and 2022, respectively, RME has invested, and continues to invest in building our capacity and customer delivery capabilities in the region.

“Latin America is home to some of RME’s oldest and most loyal customers, with well-maintained RUSSELL MRMs routinely exceeding 20 years of field operation. An unwavering dedication to precision engineering and quality manufacturing ensures our mill relining systems perform optimally, translating to a lower total cost of ownership and higher return on investment for our customers across Latin America and beyond.

“With more than 100 RME employees in Latin America, the region is also home to RME’s largest cohort of specialised local technical staff, outside Australia. We are committed to transferring our knowledge and skills to benefit career development of local employees, as well as their families and communities, while ultimately improving the safety of our customers’ reline crews and mill relining productivity. As we celebrate 20 years in South America, and also approach 40 years since RME was founded, we look to the future and remain deeply committed to expanding our business in Latin America.”

The first commercial adoption of THUNDERBOLT SKYWAY, RME’s technology that roboticises the operation of THUNDERBOLT Recoilless Hammer for safer and faster worn liner knock-in, was in Panama.

Securing this initial site in 2019 was an important step in commercialising RME’s advanced relining methods and technologies. Not only did the company gain valuable insights for its innovation program, but this installation demonstrated to industry that it’s possible to eliminate fatal risk and move workers out of the line of fire during mill relining operations, RME says.

Dr Russell said: “RME’s Latin American customers have been early adopters of products from our world-first, award-winning RME Advanced Technology Mill Relining System that ultimately allows mill operators to relocate crews to work outside the mill during liner exchange and achieve step-change improvements in safety and relining speed.

“Thanks to their safety leadership, over 30 relines globally, utilising various products from the RME Advanced Technology Mill Relining System, have demonstrated the system’s broad applicability to diverse mine sites, especially in Latin America which operates some of the world’s largest mills, long-life mines and high-altitude sites.

“The region continues to work at the forefront of advanced safety and automation technology adoption with growing interest and investment in the world’s best safety technologies.”

RUSSELL MINERAL EQUIPMENT to highlight mill relining engineering progress in 40-year anniversary campaign

Automation, Comminution of minerals, Equipment maintenance, Mining maintenance, Mining services, , , ,

Mill relining systems OEM, RUSSELL MINERAL EQUIPMENT (RME), has launched a global campaign celebrating the company’s upcoming 40-year anniversary, highlighting its engineering and pioneering progress from the past four decades.

RME Founder, Executive Chairman and Chief Engineer, Dr John Russell, said: “Since 1985, RME has innovated mill relining technologies and services with an unwavering commitment to improving the safety and productivity of our customers’ operations and the safety and development of our people. We are also proud of the local jobs we have created, our contribution to Australia’s sovereign industrial capabilities, and our efforts to better the communities in which we operate.

“It has taken 40 years of persistent innovation and enduring commitment from an exceptionally talented team at RME, forward-thinking customers and reliable suppliers.”

Launching today, the “40 Years of Innovation | We are RME” year-long campaign will showcase RME’s ground-breaking engineering innovations, the stories of the people who have made them possible, and the impact they have had on safety and productivity.

The anniversary campaign will also explore how RME continues to shape the future of the industry with pioneering innovations that enhance its customers’ ability to produce minerals, like copper, necessary for the energy transition. This includes RME’s recently announced world-first semi-automated mill relining system. It enables faster mill relining and unmatched safety with zero personnel required inside the mill during liner
exchange.

To mark the launch of the campaign, RME is releasing a new “We are RME” film. Featuring RME team members and local suppliers, the film shines a light on the characteristics, achievements and aspiration that set RME apart.

One of 25 RUSSELL TWIN Mill Relining Machine sets, where two machines work side-by-side as a system to increase the speed of the relining process

RME Non-Executive Director Dr Peter Rubie, who held the role of Chief Engineer at RME until 2019, said: “Whether it’s our 400 kg RUSSELL Mill Liner Handlers or 10-t-capacity RUSSELL Mill Relining Machines, our durable technology solutions are built to last with 90% of those we’ve manufactured in the past 40 years still in operation.

“In partnership with our customers, we have set new industry-wide safety standards. And with safety continuing to drive the evolution of our advanced technologies, we can now perform liner exchange with zero personnel inside the mill.

“RME was founded on the belief that we can make things better. Through ‘juntos’, meaning our togetherness, collaborating across RME teams and with industry, we continue to push the boundaries and pioneer new means to continually improve industry safety standards and productivity gains for mill relining.”

RME aspires to improve the human condition through responsible access to metals at lower cost, it says.

Dr Russell added: “It’s an aspiration that sees us charged with the responsibility of our people and customers’ safety and wellbeing. And in the race to a carbon neutral future, it sees us charged with the responsibility of enhancing our customers’ ability to meet the growing demand for the metals and minerals essential for the energy transition.

“Furthermore, RME’s liner exchange machines are electro-hydraulically powered, and unlike fossil fuel-driven mining equipment, are ready for sustainable energy sources without requiring power system modifications.

“RME believes that future development must balance social, economic and environmental sustainability for the ongoing improvement of the human condition. That same belief underpins our inventions.

“Through collaboration with our customers and suppliers, we have made mill relining safer and faster, while also positively impacting local jobs, livelihoods and living standards in the regions where we operate.

“Forty years on, we remain steadfast in our aspiration as the world strives for a carbon neutral future.”

John Russell founded RME in 1985 in Toowoomba, Queensland, setting out to mechanise the mill relining process to improve safety, shorten reline times and increase mine site profitability. Through a dedicated and highly skilled team, loyal and forward-thinking customers, and dependable suppliers who are integral to RME’s success, RME has grown to support customers in 64 countries, with 13 international sales and service centres, employing more than 450 people worldwide. Today, there are more than 440 mine sites across the planet served by RME’s equipment and services, including more than 570 RUSSELL Mill Relining Machines.

From enabling the development of larger liners that reduced the total number of pieces requiring change out to the creation of larger SAG mills, RME’s suite of mill relining technologies have changed grinding mill relining, globally.

RME heralds ‘world-first’ semi-automated mill relining system deployment

Automation, Equipment maintenance, Mineral processing, Mining equipment, Mining services, Sustainable mining, , , , , , , , , , , , , , ,

Mill relining systems manufacturer RUSSELL MINERAL EQUIPMENT (RME) has deployed what it says is the world’s first semi-automated mill relining system, delivering significant safety and commercial outcomes for its customer and the wider industry.

The reduction in mill relining risks and shutdown duration was achieved through a combination of: roboticising RME’s mature and proven technologies; compatible liner and bolt design; and strong collaboration and change management with site management and reline crews.

RME says its automated system addresses the two main phases of mill relining: worn liner removal and new liner placement, and enables the completion of these necessary maintenance processes without anyone inside the mill. This system was developed and implemented in close collaboration with some of RME’s existing customers, including PT Freeport Indonesia (PT-FI).

RME Founder, Executive Chairman and Chief Engineer, Dr John Russell, describes the new paradigm for fast, automated mill relines as the ultimate in safety and improved commercial performance for concentrators.

He said: “RME’s goal has been to enable our customers to reline mills with no one inside, providing them with remarkable safety and efficiency benefits. By eliminating human-machine interaction, we can speed up the machines and relining processes, consistently and repeatably. This advanced capability is now a reality.

“We are grateful to our customers, and to our liner and bolt technology partners, for their shared commitment to achieving these results. I would also like to recognise and thank our team at RME who has made our shared vision a reality.”

The results achieved to date can be attributed to RME’s systems engineering approach, it says. Safety inside and outside the mill was the priority and every step was carefully reviewed according to RME’s 24 Steps to Mill Relining Standard.

“We understood from our 35-plus years as an OEM that to safely automate mill relining, we would need to consider the many interdependent tasks across the entire process,” Russell added.

“The engineering result is now a tightly-integrated system of advanced modular technologies that automate manual repetitive tasks, eliminate risks and speeds-up relining.”

Consequently, RME’s automated system enables a staged implementation whereby upgrades happen within planned maintenance windows over multiple reline events. This ensures customers will not experience additional costly mill downtime scenarios.

One major advantage of RME’s semi-automated mill relining system is that its underpinning technologies are well-established and well-used by the industry, according to the company.

Dr Peter Rubie, who held the role of Chief Engineer at RME until 2019 and is a Non-Executive Director at RME, played a key role in the development of the company’s automation technologies.

“Mining can be conservative when adopting new technologies, due to economic risk,” Dr Rubie said. “For some of our customers, even one hour of downtime can cost upwards of $200,000 of production. We can avoid these impacts by automating existing proven systems. The beauty of RME’s mill relining technologies ecosystem is that the elements are modular and future-proofed. Miners of all sizes can deploy the base components and then incorporate additional automation steps at their own pace.”

The centrepiece of RME’s semi-automated mill relining system – the RUSSELL 7 Model R AutoMotion™ Mill Relining Machine (MRM) – is a highly advanced configuration of the industry’s most adopted 7-axis liner exchange machine, the RUSSELL 7 MRM.

It is complemented by THUNDERBOLT SKYWAY, a semi-automated knock-in system used on the exterior of the mill. Operational since 2020 at sites in Central America and Indonesia, SKYWAY is well-proven, the company says. This technology is now also available as a portable lift-in solution called THUNDERBOLT SKYPORT. It is another automation of RME’s established technology that increases asset utilisation by being sharable between mills onsite.

These systems, working together with INSIDEOUT™ Technology tooling and compatible liner and bolt design, can grab knocked-in worn liners off the shell or from the charge, and place new liners against the shell with millimetre precision and without personnel working inside the mill, according to the company. The securing of liners, nuts and bolts from the mill’s exterior can also now be achieved using RME BOLTBOSS.

RME has been collaborating with customers across several sites to progressively automate mill relining, including upskilling their customers’ local crews.

Analysis of historical reline shutdown data using conventional relining methods, compared with filmed data using some, but not all, of RME’s automated mill relining technology suite, reports a 65% risk reduction for activities inside the mill and 30% productivity uplift for a 38 ft SAG mill, RME says.

Following a staged implementation, PT-FI recently completed its first reline using the combination of THUNDERBOLT SKYWAY and the RUSSELL 7 Model R AutoMotion MRM. While the performance data is currently being analysed, early indications point to an even greater reduction in risk and increase in productivity than was originally targeted.

Director Metallurgy and Strategic Planning at Freeport-McMoRan, Dr John Wilmot, summed up the outcomes FCX is seeing as safer and faster mill relining at the recent SAG 2023 conference in Vancouver, Canada.

“PT-FI Indonesia has largely removed crew from inside the mill as we reline,” he said. “While there are still a few residual activities where we need to enter, such as wash-down, we’re executing relines faster and safer than before. Mill relining is no longer on the critical path.

“RME’s modular systems approach enabled us to progressively implement the technology, which meant we could quantify the safety and productivity improvements at each reline event, even as the new technology was being deployed.

“The staged implementation also provided an opportunity to create strong buy-in from our reline crew. In our experience, when the crew is part of the optimisation journey, the change program is infinitely more successful. At PT-FI Indonesia, our reline crew has now taken full ownership of the process.

“Leveraging RME’s equipment and methodologies, as well as the compatible liner and bolt designs, our crew has experienced the difference that automation can make. They’ve found it to be safer and faster, and they won’t go back to conventional methods. We’re incredibly proud of their work. By collaborating closely with all the stakeholders involved, we are engineering the risk out of mill relining.

“We believe RME’s collaborative and staged approach can serve as a model for the mineral processing industry. It is already achieving step-changes in safety and mill availability for our customers and we’re excited to see the impact it may have industry-wide.”

Dr Russell concluded: “We have now completed more than 30 real world relines using the various products of RME’s Advanced Technology suite. It gives me the confidence to present our system as the safest solution for our industry. And the data we’re seeing from the 30-plus relines, gives me the confidence to state that this system better for productivity.

“The transition to net zero requires an enormous increase in the minerals that are essential to the decarbonisation of our economies. We are delighted to be able to play a part in safely speeding up the production of those minerals. We’ve achieved these results in partnership with our customers, using the same pioneering mindset with which we’ve approached the past 35 years.”

RME announces THUNDERBOLT MAGNUM Recoilless Hammer range release

Automation, Equipment maintenance, Mineral processing, Mining maintenance, Mining services, , , , , , , , , , , , , ,

RUSSELL MINERAL EQUIPMENT (RME) says it is marking the official release of its fourth-generation recoilless hammer with a special introductory bundle offer for its customers – the ‘THUNDERBOLT MAGNUM Precision Pack’.

This all-inclusive pack offers incredible value and includes both the THUNDERBOLT MAGNUM 2000 and THUNDERBOLT MAGNUM 1000 Recoilless Hammers (the latter included at no cost), the THUNDERBOLT MAGNUM Power Pack (swappable between both models), the higher-reach THUNDERBOLT MAGNUM Mobile Jib (useable across the entire THUNDERBOLT range), as well as a comprehensive set of ancillaries and spares, according to the company.

With the THUNDERBOLT MAGNUM 1000 HAMMER included at no cost, the ‘THUNDERBOLT MAGNUM Precision Pack’ represents 20% off the standard price of the individual equipment purchased separately, RMW says. This exclusive offer is available immediately on all orders placed before December 31, 2021, with a delivery date prior to June 30, 2022.

Christian Kramer, THUNDERBOLT Product Manager, RME, says: “We know from 35-plus years partnering with customers on mill relines, there’s no one-size-fits-all solution to worn liner bolt knock-in. In fact, industry benchmark operations will use the hardest hitting hammers for difficult-to-dislodge bolts at discharge end and breaking-in on the first inch, then swap to a high repetition hammer for ploughing through shell lifter liners.

“This is why we’re excited about the new THUNDERBOLT MAGNUM Precision Pack. Not only do MAGNUMs hit harder and faster than the previous range, but also, when paired together, they provide four selectable levels of power for an even greater ability to select precisely the right level of power for the specific knock-in application. Combined they’ll reduce mission-critical relining knock-in hours, especially on high-wear relines, which means higher mill availability.”

In developing the new THUNDERBOLT MAGNUM Recoilless Hammers, RME applied 10,000-plus hours of research and development using customer-led design principles, to deliver quantifiable upgrades in strike energy, speed, serviceability and operator safety. The range sports two ergonomically designed hammers with each offering customers a unique advantage to shorten the mill reline knock-in phase, it says.

Designed specifically for large and medium SAG and AG mills, the THUNDERBOLT MAGNUM 2000 delivers an incredible 2,000 joules per blow 70 times a minute to plough through the toughest of knock-in phases, such as tough, stuck and deeply-wedged liner bolt bolts at a mill’s discharge end or breaking-in shell liners on the first inch, with ease, RME says. In initial commercial trials, the MAGNUM 2000 has even demonstrated the ability to knock-in peened liners without resorting to dangerous and time consuming lancing, the company claims.

“The THUNDERBOLT MAGNUM 1000 will excel in any reline environment across SAG, AG and ball mills small, medium and large,” the company says. “Its accelerated strike rate up to 1,000 joules 140 times a minute outperforms every other liner removal tool when it comes to work-rate speed and safety.”

John Russell, Founder and Executive Chairman, RME, says: “When the first-generation THUNDERBOLT was released in 1997, it was a game changer for the minerals processing industry. As the world’s only true recoilless hammer, it replaced hazardous manual methods and unfit-for-purpose tools which seriously jeopardise reline efficiency and operator safety. The fourth-generation THUNDERBOLT MAGNUMs not only build on RME’s fundamental fast-reliable-safe principles, they improve on them in every way. We’re so pleased to give our customers early and exclusive access to this incredible time-saving mill relining technology through the new THUNDERBOLT MAGNUM Precision Pack.”

Additional feature highlights exclusive to the THUNDERBOLT MAGNUM range, RME says, include:

  • Intelligent programmable power for precision performance – THUNDERBOLT MAGNUMs usher in a new ‘MAGNUM Mode’ which allows operators to program strike energy and speed for greater safety, precision and control. This selectable power also reduces the risk of high-velocity bolt projectiles, which can damage mill relining equipment and put crew at-risk, at the end of liner bolt knock-in.
  • Extended service intervals – Service intervals on the new MAGNUMs have increased by 150% to 100,000 blows through engineering and the highest manufacturing standards. Longer life components, improved component accessibility, smarter diagnostics and improved shock absorption reduces maintenance requirements for greater equipment uptime and reliabilit.
  • Smarter condition monitoring – New THUNDERBOLT MAGNUM Power Packs feature new sensors and diagnostic controls for improved performance monitoring and maintenance optimisation. Optimal tuning and blow data is now stored within the hammer for accurate operational insights and better lifecycle decision making. The new MAGNUM Power Pack is swappable between the MAGNUM 1000 and MAGNUM 2000 Hammers for efficient total cost of ownership.
  • Designed to provide the most comfortable, and safest operator experience – Improved ergonomics and a 90% reduction in recoil dry fire shock minimises both machine stress and reline crew fatigue. Hydraulic systems have also been redesigned for improved operational safety and use. A dual-action contact trigger safety mechanism eliminates risk of accidental firing. Streamlined operator inputs and improved mechanical and electrical controls protect crew working around the hammer and enhance the safety of mill reline operations.
  • Safer steadier suspension – With this product launch comes a new higher-reach THUNDERBOLT MAGNUM Mobile Jib with greater clearances, upgraded stability and a safety brake. This higher reach means access to more rows of liner bolts and can reduce the number of inching movements and inching time per reline. The MAGNUM jib can also be used across the entire hydraulic THUNDERBOLT Recoilless Hammer range.

Metso Outotec ups mill relinine equipment capacity with MRM

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , , , ,

Metso Outotec is extending its mill reline equipment offering with a high-capacity Mill Reline Machine (MRM).

The new robust MRM has a capacity of 4,000 kg, enabling easy and safe replacement of steel lining systems inside even the largest grinding mills, according to the company.

“Replacing steel lining systems inside the confined space of grinding mills is a time-consuming and demanding job requiring strict safety measures and highly reliable equipment,” Jared Le Cras, Senior Manager, Mill Reline Equipment at Metso Outotec, said. “With the addition of the high-capacity MRM, Metso Outotec now provides a comprehensive range of Mill Reline Machines designed to ISO and IEC standards. The new MRM is designed for heavy-duty lining replacement tasks, with safety and efficiency as our top priorities.”

Benefits of the Metso Outotec MRM, according to the company, include efficient mill relining enabled by unique mechanical design features; maximised reliability, thanks to easy data access and spares replacement; minimised risk, thanks to safety features; and comprehensive service support via Metso Outotec’s global service network

In addition to mill reline machines, Metso Outotec’s mill reline equipment offering includes feed chute transporters, Tube MRMs and bolt hammers.