Case Study Product – DynaPrime
Problem: Large sized mills using traditionally used steel liners had a lower liner life leading to higher installation downtime. Higher downtime accounted for unplanned shutdown leading to lower reliability. Further, constant replacement of steel liners also had concerns relating to installation safety.
Our solution: Upon critical examining of the dynamics of the mill, we offered DynaPrime, with its improved profile and material composition to cater to higher life. DynaPrime was designed with lesser number of pieces and fixing points which ensured faster installation. We incorporated new design with bolting from outside and lesser weight of the lining which eliminated the risk during the installation of the liner.
Result: Introduction of DynaPrime in designated mill resulted in 50% increase in life of the liner (from 12 months to 18 months). Further, there was 52% decrease in the number of pieces installed, 35% decrease in the total weight of the liner and 24% decrease in the number of bolts installed. Also, the installation time of DynaPrime in a mill was only 23 hours compared to 46 hours for the traditional steel liners, which led to 25% reduction in installation manpower. The overall power consumption also reduced by 5.2% per year in DynaPrime installed mills.
DynaPrime had a multi-faceted advantage over the traditional steel liners used in the large sized mills which led to an increase in asset productivity, reduction of operating expenses, reduction of risk, improvement in safety and improvement in environment sustainability. Following are the key advantages of DynaPrime.
|Increase Asset Productivity||Reduce Operating Expenses||Reduce risk||Improve Safety||Improve Environmental Sustainability|
|Increase mill availability to process more ore||Lower maintenance cost||Do away with unplanned shut-down||Installation from outside.||Lower CEE required, enabling reduction in carbon footprint|
|Increase mill operation time as a result of faster relining||Lower energy expenses||Better liner profile stability throughout the campaign||Reduces the environmental contamination|
|Increase life as per plant requirement||Less personnel required for installation|
|Increase ball charge volume due to decrease in liner weight||Faster reline due to lesser number of fixings for liner installation|
Case Study Product – Chute
Problem: Gold mines in Canada suffered from uneven distribution of mill discharge. Our objective was to get an even distribution of mill discharge with 50% solid reporting on each outlet.
Solution: Upon critical examination, it was understood that the percentage of solid distribution was uneven between two feeder boxes and as a result the screens downstream were either underfed or overfed. We offered our new tapered discharge chute, with its improved design and a rock box kind of arrangement.
Result: Our chute resulted in an almost even split as desired for the circuit. Further, the liner selection was optimised to suit the new design and maximise the liner life. This resulted in the overall improvement in the performance and the increased downstream circuit efficiency.
Case Study Product – Trommel
Problem: Copper mines suffered from regular shutdowns due to the short life of the trammel panels. Our objective was to improve the life of the trommel panel for greater productivity.
Solution: Upon critical examination, it was understood that the design of the panel was not in line with the wear rate based on the operating conditions. Therefore, the design of the panel was optimized to counteract the wear rate with an improved panel.
Result: Our heavy duty rubber trommel panels optimized for each specification resulted in an increase of the life of the panels by 50% (from four months to six months), 33.33% reduction in the number of shutdowns per annum and 22.22% reduction in the cost per tonne of the trammel panels.
Case Study Product – Centrax
Problem: Iron ore mines in India suffered from frequent tripping, due to exaggerated belt sway which resulted in unscheduled shutdown to clean the spillage. Our objective was to control the belt sway, stop unscheduled shutdowns and eliminate the damage to the belt and the structure.
Solution: Upon critical examination, it was understood that the tripping was due to the high belt sway. The belt was analysed section wise to identify the starting points of sway and Centrax was offered in identified locations to arrest the belt sway.
Result: Centrax resulted in reduction of the belt sway from 80-100mm to 40-50mm, which resulted in tripping of the belt from 10 times in a month to zero. The reduced belt sway also increased the belt life from 10 months to 13 months and provided an annual savings of ₹ 1.1 million.