Mill Liner Wear Monitoring - Industrial Technologies Supply

Copper mining operations face high stakes when it comes to unplanned downtime. Mill liner failures in Semi-Autogenous Grinding (SAG) mills can result in significant financial losses due to production stoppage. The Mill Liner Wear Monitoring System is changing this dynamic, offering a new approach to mill maintenance. This system enables predictive maintenance and timely replacement of mill liners, effectively preventing unplanned downtime. This article examines the success of this technology in a copper processing plant, achieved through collaboration with a leading Mill Liner OEM.

Background

A mining company operates a SAG mill with the following operational metrics:

Mill Capacity: 1500 tons per hour
Average Revenue per Ton: $50
Operational Hours: 24 hours/day
Operational Days: 365 days/year
Average Downtime due to Liner Failure: 8 hours

Costs of Liner Failure

Lost Production per Hour: 1500 tons/hour * $50/ton = $75,000/hour
Total Lost Production for 8 Hours: $75,000/hour * 8 hours = $600,000

In addition to the direct financial loss from production stoppage, there are indirect costs such as labour, maintenance, and potential damage to other mill components.

Introducing Mill Liner Wear Monitoring System

The Mill Liner Wear Monitoring System, costing $30,000, provides real-time monitoring of liner wear, allowing for predictive maintenance and timely replacement of liners before failure occurs.

Financial Analysis

Cost of the Mill Liner Wear Monitoring System:

Initial Purchase: $30,000

Savings from Avoided Downtime:

Estimated Number of Avoided Downtime Incidents per Year: 2
Savings per Incident: $600,000
Total Annual Savings: 2 * $600,000 = $1,200,000

Net Benefit:

Annual Savings: $1,200,000
Cost of 2Censor System: $30,000
Net Annual Benefit: $1,200,000 – $30,000 = $1,170,000

Return on Investment (ROI):

ROI = (Net Annual Benefit / Cost of System) * 100 = ($1,170,000 / $30,000) * 100 = 3900%

The Mill Liner Wear Monitoring System also offers intangible benefits:

Enhanced Safety: Reducing the likelihood of sudden liner failures minimises the risk of injury to personnel.
Improved Maintenance Planning: Predictive maintenance schedules can be better planned, reducing the strain on maintenance teams and improving overall mill efficiency.
Extended Equipment Life: Timely replacement based on wear data extended the lifespan of mill liners, reducing replacement frequency.

The successful implementation of the system was facilitated by a strategic collaboration with a leading Mill Liner OEM. This partnership ensured the 2Censor Mill Liner Sensor System was integrated seamlessly into the mill’s infrastructure, maximising its effectiveness and reliability.

Conclusion

The implementation of the Mill Liner Wear Monitoring 2Censor System in SAG mill liners showcases the transformative impact of data-driven maintenance strategies in the mining industry. With an initial cost of $30,000, the system can prevent at least two significant downtime incidents annually, resulting in a net annual benefit of $1,170,000 and an impressive ROI of 3900%. By accurately predicting and managing liner wear, End-user not only improved operational efficiency and reduced costs but also ensured a safer work environment. This case study underscores the importance of monitoring wear in critical equipment, paving the way for enhanced productivity and sustainability in mining operations.

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