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Setting Measurement in Primary Crusher

Faena: Andina Division

Deadline 16/11/2022

Closing Time 4:00 pm

During the ore size reduction process, one of the most relevant operational variables is the primary crushing discharge setting, which ensures the required particle size profile to feed the subsequent comminution stages. This variable is controlled through daily measurements and adjustments, thus compensating the wear of the liners that are in contact with the ore. At Codelco Andina Division, the primary crusher is a 63 x 114 inch Thyssen-Krupp gyratory crusher, which must maintain its discharge setting at 6.5 inches.

Identify technological solutions to determine the setting of the primary crusher by optimizing the frequency, time and accuracy of the measurements. The scouting process could lead to identify and select suppliers for a competitive process of supply or purchase, whose scope will be defined according to the degree of maturity of the proposals that apply to this open innovation process, which could lead to a pilot validation test, or to an implementation if they are relevant and meet the evaluation and selection criteria defined by Codelco.

  • It should consider minimal or no human intervention during measurements.
  • A system that delivers the data online is desirable, with reportability in the control room or wherever the client specifies.
  • The data must be representative of the entire discharge perimeter of the crusher. A point measurement is not sufficient.
  • The minimum accuracy required is + 1 mm.
  • The minimum required frequency is 1 measurement per day.
  • A solution that also allows measurement and reporting of crusher liner wear is desirable.
  • For solutions installed around the crusher, its components must be hinged or removable so as not to interfere with maintenance tasks (e.g. change of liners, change of post or others).
  • The system must have heavy duty characteristics, with high resistance to adverse environmental and climatic conditions such as wind, fog, rain, snow, humidity, particulate material, mineral projection and impacts, among others.
  • It must be compatible with the infrastructure available at Codelco and must not generate operational interferences for its installation, operation and maintenance.
  • The required degree of maturity is a TRL greater than or equal to 6, i.e. it must have at least one prototype validated in a complex or relevant environment.
  • Consultancies and advisory services.
  • Solutions requiring lockout/tagout of the primary crusher.

Implement a new setting measurement system for the primary crusher to replace the current system and to ensure the granulometry of the ore feeding the secondary crusher.

  • Variability in the discharge granulometry of the primary crusher.
  • Lower performance of the subsequent comminution stages and thus, lower production.
  • Risk of accidents due to manual measurement.


It is measured with a modelling clay sphere of approximately 2 kg, easily deformable, which is lowered by means of a 12 m rope to the point of least distance between the crusher shells (liners). The time used is 20 to 30 minutes with an empty crusher.

No new technologies have been tested.