Tag Archives: mine maintenance

Boliden Kevitsa collaborating on process plant maintenance

Base metals, Comminution of minerals, Communications in mining, Equipment maintenance, IoT, Mine operation news, Mineral processing, Mining equipment, Mining maintenance, Mining services, Mining software, , , , , , , , , , , , ,

Boliden is a front-runner when it comes to applying technology and innovation to its Europe-based mines, and the company is now leading an industry move in condition monitoring and predictive maintenance in its process plants.

At its Kevitsa copper-nickel mine, 130 km north of the Arctic Circle in Finland, Boliden has been collaborating with the likes of IBM Maximo, OSISoft, SKF and Metso on condition monitoring and predictive maintenance solutions, according to Sami Pelkonen, Maintenance and Engineering Manager at Boliden Kevitsa.

Expansion in the plans

The mine is in the throes of an SEK800 million ($82 million) expansion that will see plant throughput go from 7.8 Mt/y to 9.5 Mt/y. This involves the addition of a new autogenous mill and peripheral equipment (including a new Metso MF series screen), and a new mill building. Commissioning of the new equipment is expected in 2020, with the mine reaching full 9.5 Mt/y capacity in 2021.

With this expansion going on, plant maintenance has moved up the agenda.

Some 80% of process plant maintenance is currently pre-scheduled, with the Kevitsa mine achieving, on average, 93% availability from its equipment, according to Pelkonen, but Boliden Kevitsa is looking to increase these numbers.

Pelkonen told IM late in October that the Kevitsa mine has been looking to acquire “good quality…and useful data to support our daily maintenance operations and procedures” at its plant. This is all part of the company’s plan to increase uptime and cut costs at the operation.

As part of this initiative, it installed the IBM Maximo asset management system in May of this year. At the same time, the operation has been working with the Boliden Mines Technology Department on a wider asset management program.

When it comes to plant reliability, Boliden Kevitsa has enlisted the help of SKF (for condition monitoring of bearings throughout the plant), OSISoft for process data acquisition, and Metso to ensure uptime of mineral processing equipment is maximised and unplanned downtime is reduced.

Partnering for performance

The partnership with Metso dates back to before the mine was acquired by Boliden in 2016, but in recent years the two have collaborated on crusher and mill uptime projects, with the OEM supplying mill liners and wear parts that can be switched out quickly and cost effectively. The two firms have also been in constant communication about accessing and analysing valuable process plant data during the last three years.

When the mine acquired a new MF screen from Metso in May (pictured), it decided now was the time to trial the new Metso Metrics predictive maintenance platform in this part of the flowsheet.

Pelkonen explained: “After the increase in production (to 9.5 Mt/y), the front end will be even more critical for us, so we have to be aware if any failures are developing in our front end; especially in our screen.”

The remote location of Kevitsa, situated some 40 km by road from Sodankylä, is also behind the need for this type of condition monitoring and predictive maintenance.

“If something happens like we have an equipment failure, it takes around one hour for our employees to get to the mine,” he said. “Condition monitoring helps us address the need to get resources to site in the correct time.”

The Metso Metrics test paid off almost instantly, when, soon after installation, the company noticed there was something wrong with the running speed of the screen.

“The indication we received from Metso Metrics helped us map out that there were two broken V belts. We were able to cut the downtime to a minimum thanks to the information coming from Metrics,” Pelkonen explained.

Sami Pelkonen was speaking to IM as part of an upcoming Insight Interview with experts from Boliden Kevitsa and Metso that will be published in early-2020

H-E Parts to work on mobile equipment fleets at Glencore coal mines

Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , , , ,

H-E Parts says it has been awarded a one-year supply agreement from Glencore that will see the company supply and overhaul new and service exchange radiators on mobile equipment fleets across 24 coal mines in Australia.

The contract with Glencore Coal Assets Australia has the provision for a further 12-month extension based on performance and includes all ancillary mining equipment, as well as prime production mining truck, excavator and drill rig fleets.

The contract will be managed by H-E Parts’ Mining Solutions Cooling Division branches and incorporates various styles of independent radiators and complete modular nose cones, including the radiator, fan and motor and charge air cooler as a complete assembly, according to the company.

H-E Parts says: “The complete range of COR Cooling™ products are designed to provide extended service intervals, improved performance and increased productivity, whilst reducing equipment downtime and associated life cycle costs.”

Ashley Hams, Mining Solutions Vice President, said: “Through historic and ongoing service delivery as well as continuous product engineering innovation, our COR Cooling product and service lines have advanced to be a market leader.”

Hams added: “The ability to supply application specific cooling systems to our mining and industrial customers working in some of the toughest conditions in the world has demonstrated the engineering and quality prowess that H-E Parts has become synonymous with.”

H-E Parts said it believes that the partnership of the proven COR Cooling product line, combined with in-house engineering and service support, will provide a flexible, cost-effective, long-term solution for Glencore.

Earlier this week, H-E Parts announced it had acquired Allgo Engineering (Allgo). Although occurring in late 2018, H-E Parts had deferred announcement to facilitate the completion of a new 100 t facility and the upgrading of equipment and machining capabilities that will allow Allgo to handle some of the largest mining, marine and oil & gas components required by the Western Australia market, it said.

Petro-Canada Lubricants bolsters fleet protection with new engine oils

Environmental, Equipment maintenance, Mining consumables, Mining services, Sustainable mining, , ,

Petro-Canada Lubricants has expanded its TRAXON™ and DURON engine oil product lines with the launches of DURON™ Advanced 5W-30 and TRAXON Synthetic 75W-85.

The company, a HollyFrontier business, said the introduction of these new oils demonstrates its continued product innovation to help fleets meet new and emerging market trends.

DURON Advanced 5W-30 is a fully synthetic formulation designed to meet and exceed the requirements of the American Petroleum Institute’s (API) FA-4 standard. It has also been approved by major diesel engine original equipment manufacturers (OEMs) Cummins and Detroit Diesel.

This product line offers durable low viscosity, high performing synthetic and synthetic blend heavy duty diesel engine oils that are designed for emerging and future fuel-efficient engines, the company said. “These oils provide enhanced fuel economy, durability, engine protection and shear stability for the latest heavy-duty engines.”

TRAXON Synthetic 75W-85, meanwhile, expands the existing TRAXON Synthetic range providing fleet owners and operators with enhanced efficiency and long-lasting wear protection that can lead to longer equipment life and reduced unplanned downtime and associated maintenance costs.

“Offering year-round performance in the harshest environments, TRAXON Synthetic 75W-85 provides easier start-ups and improved cold weather shifting for manual transmissions, hypoid gears and rear axles,” the company said.

This low viscosity hypoid gear oil is designed to meet API Gear Lubricant Service GL-5 and API MT-1 Gear Lubricant standards and MACK GO-J standards for heavy-duty manual transmissions. It is also approved against the SAE J2360 Global Standard, the company said. The oil is suitable for use where Volvo 1273, 12 (97312) and Meritor 0-76-J specifications are required.

Alex Buczek, Category Manager of Heavy-Duty Engine and Driveline Oils, Petro-Canada Lubricants, said the new oils were specifically formulated to exceed industry requirements and offer improved performance and protection for fleets.

He added: “Our entire high performance, heavy-duty product line is designed with one purpose – to protect your bottom line. Our products help to make fleet equipment longer-lasting and more reliable; therefore operations can be more productive and profitable.”

Weir Minerals takes a load off slurry pump maintenance

Comminution of minerals, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Water management, , , , , , ,

An often-overlooked component, lifting tools help keep workers safe, maximise equipment life and can reduce pump rebuild times, according to Weir Minerals.

These tools have become increasingly important for handling slurry pump parts during maintenance as processing equipment has become larger and larger.

David Russell, Trials Manager for Weir Minerals Australia, says: “We have a duty of care to our customers to ensure they remain safe when operating and maintaining our equipment. Adopting our uniquely engineered lifting tools for our slurry pumps mean that when the correct procedures are followed, it’s very safe.”

It was only in the 1990s when a Warman® AH® 20/18 pump, was one of the largest available on the market. Now, it is regarded as a medium-sized model, outdone by the likes of the Warman® MCR® 760 pump.

Weir said: “As equipment has rapidly increased in scale over the past couple of decades, Weir Minerals has developed specially engineered tools to safely disassemble and reassemble machinery, reducing the risks associated with lifting components.”

In the case of slurry pumps, Weir Minerals’ range of lifting tools are designed for use when performing wet-end overhauls. Specific lifting tools are used for impellers, throatbushes, suction covers, frame plate liner inserts, stuffing boxes, casings and volutes.

These tools have also been designed to lift multiple components together to make rebuilds easier and quicker. For example, a lifting beam has been developed that lifts a suction cover squarely with the throatbush still attached to it.
“Using purpose designed assembly equipment in accordance with OEM lifting procedures can reduce rebuild time, in some cases by up to 50%, leading to increased plant uptime and availability,” the company said.

Russell said: “When lifting pump parts weighing more than two tonnes in restricted areas, there is little room for error. Often, the components will be worn and it is crucial they can still be secured and lifted safely in accordance with the strict global standards that Weir Minerals adheres to.”

When designing lifting equipment, Weir Minerals says it also carefully considers the mechanical strength and the stresses placed on the components being lifted, since worn parts are likely to be weaker and more brittle than new parts.

When it comes to impeller lifting tools, some competitors may employ a simple hook design, increasing the risk of the impeller falling off. Weir Minerals has developed a tool with a fixed locking jaw so that the impeller eye is locked in position and the component is properly secured prior to being lifted, the company says. “This positive engagement across two points of contact ensures that components are lifted evenly and securely with minimal risk of injury,” it said.

Independently certified in each region, the tools are manufactured and sold to meet local health and safety requirements, according to the company.

Joel Goodwin, Weir Minerals’ Aftermarket Manager for Warman pumps, said: “Safety is central in everything we do at Weir Minerals.

“We are an OEM supplier who complies with global safety standards and we adopt a stage-gated development process incorporating risk assessments and product stewardship best practice for equipment design and lifting.”

ABB tightens bulk handling roller bearing offering with Dodge Safety Mount

Bulk handling, Equipment maintenance, Mining consumables, , , , ,

ABB says the built-in patented locking mechanism on its newly launched Dodge® Safety Mount spherical roller bearings reduces installation time by up to 75% compared with traditional products.

Best suited for bulk material and air handling applications, the new bearing mounts by tightening fasteners instead of using a hammer and other tools. The new system also allows for simple installation and removal from the same side of the bearing, which means only one person is needed for the task, according to ABB.

“The new mounting system replaces the blows of a hammer with the tightening of fasteners,” Jim Madsen, Dodge Mounted Roller Bearing Product Manager, ABB, said. “It also makes it faster to install large bearings, but more importantly, it makes is safer for the installer.”

Safety Mount bearings feature a triple-lip contact seal and corrosion-resistant flinger sealing system, which prevents contamination from entering the product during installation and operation, ABB says. A labyrinth seal option is available for high-speed and high-temperature applications.

Dodge Safety Mount spherical roller bearings come ready for installation of the ABB AbilityTM Smart Sensor for mounted bearings, a wireless sensor that monitors the health of bearings.

The company said: “Safety Mount spherical roller bearings combine the advantages of the Dodge Imperial family of bearings; factory sealed and greased, shaft ready out of the box, with no feeler gauges required.” They are offered in split cap and single piece housing options in standard SAF, metric SN, Type E, and Imperial housing dimensions in sizes 4-15/16” to 7” (115-170 mm).

Belzona 1814 to protect chutes, hoppers and screw conveyors

Equipment maintenance, Mining equipment, Mining maintenance, , , , , ,

Belzona has released a new epoxy-based material to, it says, resist the harshest abrasive environments typically found in the mining, cement, pulp & paper, biomass and other industries.

Belzona 1814 can be applied with a brush or a float to protect assets preventing metal loss and subsequent downtime, either on its own or as part of a system with alumina tiles, the company says.

Supplied in 30 kg units, compatible with mechanical mixers and boasting a long working life, Belzona 1814 is most suited for application to large assets, including chutes, hoppers and screw conveyors, according to Belzona.

Belzona R&D Manager, Jason Horn, said: “There was a need for a lasting abrasion protection system, which can be easily mixed in large volumes and applied over sizeable areas.

“Our second objective was to create a formulation with performance equal to our existent abrasion resistant materials, while keeping the costs down – the benefit of which could then be passed onto our end users.

“We believe, with Belzona 1814, we have produced a high performance and cost-effective system.”

Epiroc investing in 3D printing for on demand spare parts

Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining software, , , , ,

Epiroc says it is introducing a project focused on the use of 3D printing capabilities for the manufacturing of spare parts.

According to Anders Johansson, Product Manager at Epiroc, working with 3D technologies will open up unlimited possibilities for the company.

One promising technology gaining momentum is additive manufacturing or a phased build-up of an object using 3D modelling and printing, Epiroc said. This has not yet been widely developed for the mining and construction industry.

“The technology of fast details production involves the manufacturing of physical samples based on CAD-data or 3D-scanning data,” Epiroc said. “This includes the use of special equipment for layer-by-layer 3D-synthesis and practically no need of further refinement.”

Earlier in 2019, Epiroc begun to explore the opportunity to implement additive technologies in the process of manufacturing spare parts; it was after high standards of quality and accuracy with this.

Johansson said: “Working with 3D technologies opens up unlimited opportunities for the company to create complex geometric shapes and maintain high quality standards.

“This technology does not only provide additional opportunities for the creation of complex parts. It also allows companies to transfer digital models around the world in minutes to manufacture spare parts right on the spot where they are needed.”

For those who use Epiroc equipment, spare parts wait time will be noticeably reduced, according to Epiroc. Consequently, equipment downtime will also decrease. In addition, the possibility of 3D printing significantly optimises the process of delivery and storage of Epiroc spare parts, which will lead to increased value for the customers, the company said.

Johansson concluded: “Thanks to the opportunities this will give, we will be able to serve our customers in new ways and, at the same time, reduce environmental impacts throughout the world, which is high on our agenda as a modern global company.”

 

Mobil lubricant switch pays off for Russia limestone quarry

Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , , ,

A Russia limestone quarry has achieved an annual saving of €7,900 ($8,764) after switching its Hitachi excavators to Mobil DTE 10 Excel™ 46 hydraulic oil, according to ExxonMobil.

The use of this hydraulic oil, which, the company says, is specifically formulated for use in modern mobile equipment, extended oil drain intervals by 25% and also reduced filter replacements.

ExxonMobil said: “The mining company was having to drain its existing hydraulic oil every 4,000 hours but was aware that a better performance might be possible for the excavators, which weighed between 80 t and 115 t. It therefore approached ExxonMobil in the hope of extending oil life while maintaining hydraulic pump efficiency.”

Sarp Degirmenci, EAME Offer Advisor at ExxonMobil, said the company’s field engineering services (FES) team worked with the customer to identify the most suitable lubricant.

“As a result of this, they suggested a switch to Mobil DTE 10 Excel 46 hydraulic oil, which was developed to provide a long oil life and minimise deposit formation, even in hydraulic systems operating in severe conditions.

“Our engineers also recommended implementing Mobil Serv Lubricant Analysis to monitor the in-service performance of the oil.”

Regular testing revealed the optimal drain interval for Mobil DTE 10 Excel 46 hydraulic oil was 5,000 hours, an improvement of 25% on the previous grade, according to ExxonMobile. “It also revealed enhanced hydraulic pump efficiency, a reduction in deposit formation and reduced filter clogging.”

There was no unscheduled downtime during the test period, according to the company, which helped boost productivity and cut maintenance costs. The combined annual saving was estimated at €7,900.

Degirmenci said: “Mine owners need to ensure the reliable performance of all their equipment as any unscheduled downtime can damage bottom line performance. Using high performance oils and grease, in partnership with a next generation used oil analysis service, can help guarantee uptime, cut costs and improve equipment performance. This combination can help operators gain a competitive advantage in an increasingly competitive industry.”

CMS Cepcor wins plaudits for overseas crusher parts sales

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining industry recognition, Mining services, , , ,

CMS Cepcor® has been recognised for its overseas sales growth in the last three years, receiving a Queen’s Award for the second time in its history.

On this occasion, the company received the Queen’s Award for Enterprise: International Trade 2019.

“This award is due to significant sales increases in Europe, Latin America and Russia where the company has had exceptional sales growth,” CMS Cepcor said.

“The success is due to the hard work of their winning team, significant growth in spare part stock inventory and continual development of a product range to serve both modern and classic crushers.”

Spread throughout the mining and quarrying sectors, CMS Cepcor has, through prioritising service and premium quality products, continued to build trust and confidence in the business, it said.

Originally trading as Crusher Manganese Steels Ltd and founded some 30-years ago, the company, now based in Coalville, UK, employs close to 100 people and has enjoyed double-digit growth for each of the last three years, it said.

“Over the last six years, the company has invested millions of pounds in their Coalville sites, including building a new global headquarters and the opening of a 3,000 m² technical centre,” CMS Cepcor said.

On top of this, the company plans to open a new 6,000 m² global parts centre, adjacent to its technical centre, during the June quarter.

CMS Cepcor was previously awarded the Queen’s Award for Enterprise: International Trade 2012 for its export sales.

The company says it is Europe’s leading aftermarket manufacturer and supplier of crusher spare parts, mining grade crusher liners and crusher service to mining, aggregate production and associated crushing industries globally.

RPMGlobal to provide cloud-based offering for mining software solutions

Equipment maintenance, IoT, Mining equipment, Mining maintenance, Mining services, Mining software, , , ,

RPMGlobal has announced that several of its enterprise software solutions will now be available with a “cloud-hosted offering”.

RPM CEO and Managing Director, Richard Mathews, said moving its software solutions to the ‘cloud’ had always been a goal of the company. “However, we knew that to accomplish this we had to re-architect our suite of software products to enable us to offer this alternative method of delivery to our customers.

“Six years of development later and all the pieces are now in place for RPM to offer our solutions to customers through a hosted offering using a dedicated cloud delivery team as evidenced by our recent sale of a cloud-based solution to a North American customer.”

RPM’s products, which include software for mine design & reserving, mine enterprise planning, mine planning & scheduling, mining simulation, mining financial budgeting, mine operation, and mine, asset & equipment maintenance, have traditionally been deployed by its customers at their mine sites or corporate offices on desktops or servers.

“This approach meant there were some inherent restrictions with respect to accessing the software including the reliability, accessibility and speed of private network connections as well as hardware performance limiting the solutions true capabilities,” RPMGlobal said.

RPM’s cloud hosting solution enables users to access RPM software products, applications, solutions and their associated data from anywhere, anytime from inside a safe, secure and high-performance computing environment, according to the company.

Mathews said: “Whilst we can now offer our customers a cloud-based solution, we will also continue to offer our traditional delivery approaches. This is just another example of how our Intelligent Mining software suite of products gives miners, mining contractors and original equipment manufacturers around the world new, improved and high performing user experience options.

“Every company has different policies and visions for their computing environment, so a one-size-fits-all approach never works. There are certainly companies that want to make the transition to the cloud environment and RPM is ready to support them in this endeavour.”

Mathews concluded: “A successful cloud offering requires us to work closely with our customers and, to that end, we have established a separate team who are tasked with ensuring our customers make a smooth transition to the cloud.

“Our goal is to ensure these customers see quantifiable benefits from RPM’s previous investment made in ‘enterprising’ our products and the obvious flow-on benefits from operating in the ‘cloud’.

There is no doubt that providing software delivery via the Cloud enhances our customer’s businesses whilst improving our ability to service them through better availability, upgradeability and system up-time.”