ote outotec millmapper eng lores

8/11/2019 OTE Outotec MillMapper Eng Lores

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Benefits

n Optimizes liner life and design

n Early detection of liner failure

n Remotely operated, no manual entry required

n Higher overall mill availability

n Improved forecasting from more accurate

and reliable data

n Improved safety

Outotec MillMapper

Measure Model Manage

MillMapper (developed by Scanalyse which is now partof Outotec) is a globally patented technology for millliner condition monitoring and modelling. Unique inthe industry, MillMapper provides an unprecedentedlevel of information and allows your maintenance

and operational personnel to extend liner life cycles,optimize liner design, prevent liner failures, optimizethroughput and improve the performance of your mill.

Regular condition monitoring of mill liners helpsimprove the overall comminution performance.

Services Technical Services Comminution


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Operating principle

Scanning

Initially, the mill is scanned using a state-of-the-art laserscanner either by personnel entering the mill or remotely,by mounting the scanner on a support beam. Scanning isperformed in as little as 15 minutes and can be scheduledto coincide with your planned inspection shutdown.

Using a specially calibrated terrestrial laser scanner,MillMapper records the entire visible internal surfaceof the mill, as opposed to conventional methods whereonly a few arbitrarily selected points are measured.

Unlike Ultrasonic Thickness Gauge (UTG) and manualmeasurements, MillMapper provides liner thicknessmeasurements over the entire internal mill surface.Up to ten million thickness points are used to producea 3D model and subsequent wear tracking curves.

3D Modelling

Following the scan, the raw data is uploaded andprocessed to deliver a high denition 3D model. This is

colour-coded according to liner thickness and providespoint thickness measurements on all wear surfacesto an accuracy of 3mm. The software automaticallydetects high wear zones and asymmetric wear patterns.Cracked liners, loose plates and broken grates are alsoeasily detected.

Reporting

Following automatic detection and agging of the wearhot spots, the software produces precise wear curvesand intelligent forecasting based on trend data gatheredfrom over ten million thickness points on the liner.The reporting software also produces cross sectionaland longitudinal prole curves and reline efciencies.

Operators can therefore establish critical thresholdsthat dene reline criteria and also make informeddecisions based on automated, consistent and repeatablemeasurements followed by rigorous statistical analysis.

Worlds rst mill conditionmonitoring technologySeveral years of research in applying terrestrial laser scanners to a range of industrial machinery lead to thedevelopment of the worlds first in-situ measurement, modelling and management of liners in grinding mills.MillMappers globally patented, unique monitoring technology provides accurate measurement of liner thickness,weight and condition for the entire mill surface.

The intelligent software tracks and forecasts wear on your shell, discharge and feed end liners, providing accurateinformation on mill charge and a wide range of metallurgical parameters.

Wear curves for lifters and plates over two differentlife cycles

Feed end of SAG mill showing extreme wear patterns onInner liner


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The advanced dataprocessing convertsthe grey-scale surfacemodel to a 3D linerthickness model

Measure Model Manage

Optimizing liner design

Liner designs can be optimized by providing historicalcross-sectional and longitudinal wear plots foreach liner type. Optimized liner design can increasethroughput tonnage, extend reline schedules andminimize material wastage.

Reline forecasting

Reline forecasts are determined with advanced tonnage-based modelling techniques specically designed tocapture high wear zones within the mill.

Reline schedules can be optimized with condence, theadvanced forecasting algorithms capture dynamic wearrates over each liner lifecycle and historical data ofseveral lifecycles can be compared to the current one.

Quick and simple

A mill scan usually takes between 15 and 30 minuteswhich can be simply integrated into regular shutdown

schedules. This means a reduction in the duration ofinspection shutdowns.

MillMapper deliverables

A detailed report from the MillMapper data is generatedwithin a short t ime frame. Outotecs highly experiencedMillMapper team reviews these reports and discussesrecommendations in a one-to-one consultation. Sitesare also encouraged to download the 3D modelsand reports from their scan and, using the integratedMillMapper software, can conduct a virtual inspectionof the mill and review, in complete detail, anyparticular point.

n Detailed initial wear report n One-to-one consultation follow-up n 3D model and software

n Database package of sites wear history

Proven at site

MillMapper has provided clients with crucialrecommendations that have prevented catastrophicliner failure and subsequent ongoing damage. At oneparticular site, imminent relines were recommended

after detecting accelerated wear in several of the mills,saving over AU$18M in 2009 in potential productionlosses and repairs.

Liner wear rates and high wear proles have providedclients with the ability to forecast changeouts moreaccurately. This reliable forecasting has allowed clientsto extend shutdown cycles and liner life. By extendingscheduled shutdowns from 12 to 16 months, one clientwas able to save AU$330K in a calendar year, withan ongoing reduction in operating costs of AU$80Kper annum.

Cross sectional proles shown over complete liner life


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Improved safety

Laser scanning can be performed remotely by mountingthe scanner on a support beam. Remote scanningeliminates the need to perform a conned space entry,

thus reducing safety risks, minimizing inspectiondowntimes and negating the need for lengthy safetyprocedures.

Advantages

Through improved knowledge of liner wear, MillMappercan optimize the liner life and design, detect earlyliner failure and deliver higher overall mill availibility.

MillMapper also has the following benets overconventional thickness measurement techniques:

n Scanner mounted on a support beam forremote entry

n Improves safety by eliminating connedspace entry

n Minimizes inspection shutdown times n Captures wear data on the entire mill n Reliable reline forecasting n Optimizes liner designs

n

Denes metallurgical parameters n Identies and prevents catastrophic liner failure

Process Before MillMapper With MillMapper

Liner thickness measurement 20-30 spot measurements with UTGor basic manual techniques

10 million thickness points captured in as littleas 15 minutes

No entry required Automated, consistent, repeatable

measurement Reduced inspection downtime

Evaluate wear patternsin the mill

Rely on visual inspection and spotmeasurements

Colour-coded 3D model and indepth repor tindicating accurate wear patterns, cracks andhotspots

Calculate mill charge Estimate by counting number of liftersexposed / rely on inaccurate load cell

Highly accurate charge downtime and massmeasurement derived from scan le

Schedule reline Based on past history, spotmeasurements and estimations

Reliable forecasting Optimization with tonnage-based wear tracking

Liner prole assessment Manual spot measurements Liner thickness and prole measurements at alllocations in the mill

[email protected] 2013 Outotec Oyj. All rights reserved.

Outotec provides leading technologies and services for the sustainable use of Earths natural resources.

As the global leader in minera ls and metals proces sing t echnology , Outotec has dev eloped ove r

decades many breakthrough technologies. The company also provides innovative solutions

for industrial water treatment, the utilization of alternative energy sources and the

chemical industry. Outotec shares are listed on NASDAQ OMX Helsinki.

Scanner inserted on a beam

ote outotec millmapper eng lores

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