The Pebbles and Gravel (P&G) Plant at the Concentrator has electromagnets and metal detectors installed on the conveyor belts, especially on the belts feeding the crushers. When a non-crushable (unbreakable) metal object is detected, the system automatically stops the belt by interlocking. According to the current operating protocol, to resume operation, an operator on site must open the crusher and manually unload the material on the belt, allowing the detected object to continue its path without being processed. This procedure is repeated approximately six times per shift, affecting operational performance and generating gravel recirculation. The manual removal of uncrushables is an operationally complex task with associated risks. Their extraction can cause projections, requiring the intervention of operators with specialized personal protective equipment. Added to this are conditions that make this task even more difficult: the mineral load on the belt reaches estimated depths of between 8 and 10 cm, which prevents the visualization of metallic objects—mainly steel balls—that remain hidden under the material. In addition, visibility in these areas is reduced, particularly during night shifts, where artificial lighting is limited. The presence of dust and the use of domes on some belts to control particulate matter also restrict direct observation conditions. Failures have already been recorded in crushers due to the passage of uncrushable materials that were not detected or removed effectively, highlighting the need to strengthen the availability and reliability of this critical equipment. In this context, these findings reinforce the relevance of exploring technological solutions that optimize the detection and removal of uncrushable materials, reduce the risks associated with manual procedures, and improve the continuity and efficiency of operations.

When current systems fail to detect a metal object on the conveyor belt or when, even if detected, the manual removal protocol is ineffective due to the difficulty of locating the object among the material.

Negative impact on operational continuity and performance, as well as generating risks for operators who have to perform manual procedures under adverse conditions.

The detection of uncrushable objects is carried out using electromagnets and metal detectors installed on the conveyor belts, which have been in operation for several years and whose effectiveness varies depending on their condition and location. Once a detection is activated, the object is removed through a protocol.

Consulting, advisory services, and engineering studies.

• Technical solutions that address, either jointly or separately, the detection and/or removal of uncrushable objects on conveyor belts may be submitted.
• Capacity to detect and/or remove uncrushable metal objects, with a focus on steel balls, which are the most common.
• Contribution to reducing the operational downtime of the equipment involved, which currently registers between 5 and 6 stoppages per shift.
• Technology readiness level (TRL) equal to or higher than 5, i.e., validated in a relevant environment outside the laboratory.
• Given that the ore on the belt has an estimated depth of between 8 and 10 cm, it is desirable that the proposed technology has the ability to detect and/or remove uncrushable objects both on the surface and inside the ore load.
• Detection systems must operate online and in real time, generating alarms that allow for a timely response by the equipment involved. The false positive and false negative rates that the system may present must be clearly specified.
• For removal systems, considering that the aim is to reduce direct human intervention, automated or semi-automated solutions are desirable.
• High reliability, easy adaptability, and low maintenance complexity, considering the demanding environmental conditions of the operation, such as the presence of particulate matter, material projections, and low visibility

Identify technological solutions that enable the efficient detection and/or removal of uncrushable objects present on the conveyor belts at the P&G Plant, using systems that significantly improve operational efficiency. The aim is to reduce downtime, minimize risks to personnel on site, and increase the availability and reliability of the critical equipment involved in the process.

Companies, startups, institutes, research centers, or other legally constituted entities, in accordance with the current legislation of their country of origin. Individuals are excluded from this call for proposals. We extend this invitation to promote collaboration and complement the technological and/or business capabilities of companies, startups, or other entities. For teams and consortia, the responsible institution must be clearly identified in the application.