Tag Archives: Schenck Process

Schenck displays continental comminution offering with Peru copper contract

Schenck Process has won a contract to design manufacture, supply and commission vibrating screens and feeders for the greenfield Mina Justa copper project, in Peru.

The order will see Schenck business units on four continents combine to deliver seven banana screens (across three models), five diverging pan feeders and one grizzly feeder.

Mina Justa, owned by Minsur and Empresas Copec through holding company Cumbres Andinas, is slated to produce around 100,000 t/y of copper when fully ramped up.

The screens and feeder contract will see all design completed at Schenck’s vibrating equipment design centre in Sydney, Australia, manufacture and testing in the company’s Chinese plant, custom-made screen panels from the South Africa production facility and commissioning by the aftermarket services team in Chile. The project is being managed and coordinated by the Australia-based Project Management team, Schenck said.

The screens include several mechanical and operational improvements developed on a prototype vibrating screen now undergoing site testing at an iron ore mine in Western Australia, according to the company.

“The five larger screens feature laminated side plates to maintain structural integrity and reduce stress concentrations associated with the projected process tonnages,” Schenck explained. “Additionally, machined transition flanges are welded in a low stress area to the cross beams to actively reduce fatigue, and a unique spring removal system has been fitted to facilitate and reduce downtime during spring change-outs.”

The six feeders have been designed to account for site conditions and feature a more robust design. They are also equipped with exchangeable liners and an upgraded transition hopper to improve operational availability and performance, the company said.

Each of the vibrating feeders and screens for Mina Justa is equipped with CONiQ, the company’s proprietary continuous six-dimension condition monitoring system, to track and alert operators to abnormal operating conditions. Feeder control systems have been electronically aligned with the screen’s installation, Schenck added.

Project manager, Lauren Williams, said: “This is a truly international project and, from our point of view, it is the best way to give our customer the equipment that will deliver higher process efficiency and longer service life.

“Although based on standardised platform designs for screens and feeders, each unit has been subject to a customising process to meet site and processing capacity requirements. We are delivering an integrated package of screens and feeders to optimise availability and productivity and represent the best value for money.”

Schenck Process filling screen performance data gaps with sensors

Schenck Process says performance data provided by extra sensors fitted to a prototype vibrating screen is substantially improving the understanding of operation of the equipment.

The data is also giving indicators about the overall performance of the processing cycle, according to the company.

Designed and developed in Australia by Schenck Process, the prototype screen is undergoing site trials, but the company already believes the new screen has the potential to change the way vibrating screens are developed and operated.

The standard condition monitoring system comprises two sensor nodes including six degrees of freedom MEMS accelerometers, a high-resolution accelerometer and a temperature probe. On the prototype screen, four additional sensors have been fitted, one on each corner.

Schenck Process Senior R&D Engineer, Doug Teyhan, said: “The measurement regime for the additional sensors includes spring amplitude and mean compression, allowing the estimation of tonnage and load bias (to determine if the feed is presented square to the screen or favouring a side) and the determination of spring operating characteristics and cumulative fatigue damage.

“We are also looking into the development of a predictive failure program to improve overall productivity and efficiency and significantly reduce the possibility of unplanned downtime.”

Historically, failure prediction has been determined by running components to the point of failure and assessing a mean time to this point based on a known operating history.

“The data generated by the prototype screen is utilised to estimate the operating stress of the screen at the most aggressive fatigue areas and assessing the cumulative damage of those areas based on the measurement of non-ideal operating characteristics,” Schenck Process said.

Using a Cumulative Damage System, which counts machine cycles and trend characteristics that have the potential to adversely affect vital component life expectation, the plan is to make the machine monitoring system a lead measure in predicting the potential for component failure, Schenck Process said.

“The expanded monitoring system will also provide input into machine development of the next generation of vibrating screens by filling in the unknowns in the design process with real-time field data,” the company said.

According to Teyhan, the benefits for the customer – including increased availability and improved screen performance – are substantial and have the potential to initiate improvements in the processing cycle.

“And, from a screen operation point of view, the additional data is bringing to light characteristics not previously known. It is highlighting transient feed characteristics – not visible using traditional condition monitoring techniques – that impact the loading of the screen and affect machine life expectation,” he said.

“We also believe there are potential industry-wide benefits, through new design parameters and possible changes to machine construction techniques and materials,” he added.

To optimise the greater range and scope of data the screen is generating, the company is collaboratively investigating and assessing other performance variables, it said. The potential is for control of the variability in the feed rate, more consistent performance and improved overall efficiency of the cycle.