CODELCO – Andina Division, in the new primary crushing station, will process 7000 tonnes / h of ROM (run of mine) ore to a granulometry 100% below 7 inches. This ore must feed the following crushing and grinding stages through a system of conveyor belts that include feeders and chutes (see annex 1 – click here ). Both are lined with a large number of wear plates that ideally should be replaced at the end of their useful life

Objective and scope

Identify technological solutions for monitoring wear and / or instabilities of the plates inside chutes and feeders, allowing to optimize their maintenance, replacement frequency and generate alerts in the event of detachments

Solution requirements

The proposed technological solution must consider the following requirements:

• In case of sensorization; easy to install, uninstall and maintain devices.
• Minimal or no presence of on-site workers.
• Minimal operational interference.
• High availability of monitoring systems.
• Ideally, online and real-time plate monitoring (nonexclusive)
• The proposed solution must provide reliable information and alarms that allow optimizing maintenance planning and prevention of unwanted events.
• In the case of an online monitoring system, the following must be provided: information such as portability and location, data storage and transmission capacity, energy autonomy, transmission protocols, required temperature and brightness ranges, resistance to hostile environments (IP67 or similar).
• Meet the safety and communications standards of CODELCO – Andina Division.

In the evaluation process, the following will not be considered:

• Consulting or engineering studies
• Proposals to change the plates to others of a different material.
• Proposals for changes in the design of chutes and feeders.

Challenge

There is no monitoring of the condition of wear plates, so the elements with risk of detachment or that require replacement are not identified.

Consequences

• Unforeseen fall of plates on conveyor belts and crushers with risks of generating plugging, belt breaks and damage to crushers, among others.
• High maintenance costs due to scheduled replacement of plates in good condition.
• Lower productivity of concentrator plant due to unscheduled shutdowns.

When does the problem occur?

Constantly.

How is it currently resolved?

• Replacement of plates in biweekly maintenance. Does not consider level of wear.
• Replacement of plates due to unforeseen falls

Tested technologies

Technologies have not been tested