Outotec® MillMapper and Outotec® CrusherMapper

The industry's most powerful tool in liner condition monitoring

Scanalyse, globally renowned for its technologies in mill liner condition monitoring and optimization, is now a part of Outotec. Outotec®MillMapper and Outotec®CrusherMapper are globally patented technologies and are the first in the world to measure, model and manage liners in grinding mills and crushers. These technologies provide an unprecedented level of information to sites - delivering, for example, up to 10 million thickness points in as little as 15 minutes.   

Using non-invasive 3D laser scanning with globally patented, proprietary software to create reports on key performance parameters, MillMapper and CrusherMapper are the industry’s most powerful tools in liner condition monitoring and mill performance optimization.

With this powerful tool, maintenance and operations personnel can extend liner life cycles, optimize liner design, prevent liner failures, optimize throughput and improve the overall mill performance.  By combining the expertise of Outotec and Scanalyse, clients now access truly state-of-the-art technology with value-added services over the complete lifecycle of the comminution circuit.

Measure:

state-of-the-art 3D scan and data capture of up to 10 million points on wear surface with unprecedented accuracy and consistency.

Model:

globally patented intelligent software delivers high definition 3D model - automatically detecting high wear zones and asymmetric wear patterns. Cracked liners, loose plates and broken grates are easily detected.

Manage:

unique software tools and expert advice improves efficiencies and reduces costs. The industry’s most powerful tool delivers truly performance based maintenance and operation services and allows for process optimization based on unique analysis. MillMapper and CrusherMapper technologies will optimize your mill and crusher liner operation.

 

Outotec® MillMapper 3D model
Outotec ® MillMapper
3D model Shell liners unwrapped with maximum wear profiles identified by horizontal coloured bands

Outotec ® MillMapper scanner

Scanner mounted on a support beam for remote entry

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Outotec ® MillMapper tracked cross-sectional profiles       Outotec ® MillMapper tracked longitudinal profiles
Tracked cross-sectional profiles       Tracked longitudinal profiles

 

Outotec®CrusherMapper
Laser scanning during reline shutdown (remote scanning option is available eliminating manual entry)
Outotec®CrusherMapper 3D model of crusher mantle
3D model of crusher mantle showing damage from tramp metal.
Outotec®CrusherMapper 3D model
3D model of unwrapped concave liner with asymmetric wear.

 

 

 

  

Outotec® MillMapper 3D modelOutotec®-MillMapper is a globally patented technology and is the industry standard in mill liner condition monitoring and modelling. Unique in the industry, it provides an unprecedented level of information and allows your maintenance and operational personnel to extend liner life cycles, optimise liner design, prevent liner failures, optimise throughput and improve the performance of your mill.

 

Outotec® MillMapper

MillMapper is a unique service which combines laser scanning technology with 3D modelling techniques and advanced integrated software to track and forecast wear on your shell, discharge and feed end liners. MillMapper also provides accurate information about the mill charge and a wide range of metallurgical parameters.

Measure Model Manage

Outotec’s service begins with a site visit by trained technicians to scan the mill with a state-of-the-art laser scanner. Scanning can be performed either by personnel entering the mill or by mounting the scanner on a support beam for remote scanning. Scanning is performed in as little as 15 minutes and can be scheduled to coincide with your planned inspection shutdown.

Following scanning, the raw greyscale scan data is processed by specialised technicians in our central processing centre, to produce a 3D model. Up to ten million thickness points are used to produce the 3D model and subsequent wear tracking curves. This model is colour-coded according to liner thickness and provides point thickness measurements on all wear surfaces to an accuracy of ±3 mm. The 3D Model allows areas of high wear to be located and asymmetric wear patterns to be identified. Cracked liners and loose plates are also easily detected.

Outotec ® MillMapper
3D model Shell liners unwrapped with maximum wear profiles identified by horizontal coloured bands

MillMapper's integrated reporting software produces wear curves, forecasting tables, cross-sectional and longitudinal profile curves and reline efficiencies. Reline forecasts are determined with advanced tonnage based modelling techniques specifically designed to capture high wearing zones within the mill.

Outotec provides clients with comprehensive training to allow them to interrogate the 3D model and associated report files. User-group programs are regularly conducted to provide a platform for clients to network and gain insight from each other's experiences.

Measurable Benefits 

Outotec ® MillMapper scanner

Scanner mounted on a support beam for remote entry

MillMapper has the following benefits over alternative thickness measurement techniques:

  • Improve safety by eliminating confined space entry
  • Minimize inspection shutdown times
  • Capture wear data on the entire mill
  • Reliable reline forecasting
  • Optimise liner designs
  • Define metallurgical parameters
  • Identify and prevent liner failure

Using MillMapper one client, for example, -was able to reduce the number of relines in a year from four to three. The elimination of one complete reline a year saved significant money in labour, liner costs and added production. Several clients have avoided catastrophic failure after severe localized wear was identified by MillMapper. At one particular site, imminent relines were recommended after detecting accelerated wear in several of the mills, saving over AU$18million in 2009 in potential production losses and repair.

Outotec ® MillMapper tracked cross-sectional profiles       Outotec ® MillMapper tracked longitudinal profiles
Tracked cross-sectional profiles       Tracked longitudinal profiles


Service Excellence

Outotec ® MillMapper liner wear tracking and forecasting by tonnageThe MillMapper service provides the client with four deliverables:

  • Detailed wear report
  • One-to-one consultation follow-up
  • 3D model and software
  • Database package of site’s wear history


The wear report, provided in a very short time frame, provides statistical wear tracking information, including wear curves, forecasting tables, cross-sectional and longitudinal profile curves and reline efficiency. MillMapper software automatically selects and reports on the highest wearing zone, giving you protection against unexpected wear patterns and ensuring that high wearing areas are always captured.  

The report is written by a metallurgist or engineer, followed by   recommendations in a one-to-one consultation.  Sites are also encouraged to download the 3D models and reports from their scan and, using the integrated MillMapper software, can conduct a virtual inspection of the mill and review, in complete detail, any particular point.

Outotec can also be commissioned for project work to optimise mill operation, optimise the sequencing of reline schedules, redesign liners, load cell calibration, complete reline service for grinding mills and more.

Outotec ® MillMapper mill charge reporting

 

 

Outotec®CrusherMapper is a globally patented technology, and is the next generation in condition monitoring of gyratory crushers. This world-first, in situ CrusherMapper provides detailed condition monitoring and optimisation of gyratory crushers.

Outotec®CrusherMapper
Laser scanning during reline shutdown (remote scanning option is available eliminating manual entry)

CrusherMapper is a unique service which allows your metallurgists and maintenance personnel to make informed decisions on reline scheduling and crusher operation. CrusherMapper also provides a means to identify asymmetrical wear patterns, measure CSS and OSS and optimise mantle and concave liner designs.

CrusherMapper has significant benefits over historical monitoring methods. These methods all require lengthy shutdown times, confined space entry and significant safety risks to personnel. These methods are often deemed impractical and no monitoring is performed. Manual and UTG measurements provide data subsets and do not represent the entire crusher. The accuracy of modern UTG measurements is also susceptible to operator error, complex back of liner designs and poor calibration. Unlike UTG, CrusherMapper is insensitive to common casting additives such as manganese.

Outotec®CrusherMapper table

Measure Model Manage 

Outotec’s service begins with a site visit by trained technicians to scan the crusher with a state-of-the-art laser scanner. Scanning can be performed either during a:

  • reline shutdown from the cleared dump pocket
  • inspection shutdown with a remote scanning frame
     
Outotec®CrusherMapper 3D model of crusher mantle
3D model of crusher mantle showing damage from tramp metal – reposition text so it doesn’t hide area of interest

The scan is conducted within an hour and can be scheduled to coincide with your planned shutdown.

Following scanning, the raw greyscale scan data is processed, to deliver a high definition 3D model. This model is colour-coded according to liner thickness and provides point thickness measurements on all wear surfaces to an accuracy of ±3 mm. Visual inspection of the 3D model allows rapid identification of 'hot spots' and asymmetric wear patterns on your mantle or concave liners.

CrusherMapper's integrated reporting software uses advanced tonnage-based modelling techniques for reline and liner failure date forecasting.

Outotec provides clients with comprehensive training to allow them to interrogate the 3D model and associated report files. User-group programs are regularly conducted to provide a platform for clients to network and gain insight from each other's experiences.

Outotec®CrusherMapper 3D model
3D model of unwrapped concave liner with asymmetric wear.

Measurable Benefits 

CrusherMapper has the following benefits over conventional thickness measurement techniques:

  • Outotec®CrusherMapper laser scanning during reline shutdown
     
    Improve safety by reducing or eliminating confined space entry
  • Minimise inspection shutdown times
  • Measure all crusher surfaces with accuracy
  • Optimise reline schedules
  • Optimise liner designs
  • Identify and prevent liner failure
  • Measure OSS and CSS accurately
  • Monitor spider arm condition


Using CrusherMapper has allowed some sites to nearly double their liner life. The consequent reductions in reline downtime represents significant savings in maintenance and reline costs, including labour hire, and reduced production loss.

Service Excellence

The CrusherMapper service provides the client with four deliverables:

  • Detailed wear report
  • One-to-one consultation follow-up
  • 3D model and software
  • Database package of site’s wear history
     

Outotec®CrusherMapper concave liner wear tracking and forecasting by tonnage

CrusherMapper software automatically selects and reports on the highest wearing zone, protecting operators against the impact of unpredictable wear zones and ensuring that high wearing areas are always captured.

The wear report is written by a metallurgist or engineer, followed by recommendations in a one-to-one consultation.  Sites are also encouraged to download the 3D models and reports from their scan and, using the integrated CrusherMapper software, can conduct a virtual inspection of the crusher and review, in complete detail, any particular point.

Outotec®CrusherMapper concave condition tracking
Concave condition tracking - average longitudinal profiles

 




 



 

To download your site-specific scan data and models, please click on this link

Note!  This site support section requires authentication.  Please ensure you have your username and password to access your data. For queries on the username and password, please contact: scanalyse.survey.au@outotec.com 

 

Case

Problem

Localized wear 

The most pronounced wear points cannot be determined unless they happen to be included in the limited number of points that are measured manually. The location of wear “hot spots” is not always conveniently located for manual measurement and there is a high risk that it will be missed.

Read more about the solution and outcome...

Avoiding catastrophic failure 

Lifter bars can crack and break, such as the one shown in the red circle on the right, and if it is located at the top of the mill this damage can be very difficult to see. Left unattended this will result in shell “washout” with dire consequences.

Read more about the solution and outcome... 

Avoiding catastrophic failure (2)

Liner wear rates are not always uniform along liner segments and advanced wear in one location can threaten liner “washout”, particularly when a longer life for this liner is expected. Visual means are not reliable in detecting these high wear locations. The two Outotec® MillMapper outputs below show clear erosion of the shell feed end lifter bars between 27th February and 2nd April.

Read more about the solution and outcome... 

Reliable forecasting enabling well organized scheduled maintenance 

Mill liners were scheduled for replacement at a shutdown in May 2008. Unknown to the mill operator wear rates had accelerated on the plates and several liner segments would have worn to failure limits by May. This would have been noticed in the shutdown in February however no arrangements had been made for relining. A subsequent unscheduled stoppage would have had to be organized at considerable extra cost and with severe disruption to the site.

Read more about the solution and outcome... 

Reducing the number of shutdowns by extending reline schedule 

A remote mine site with very high costs associated with shutdowns wishes to reduce the number of shutdowns in a two year period from eight to seven. A fixed 3 month reline schedule has been adhered to for several years and there is not enough reliable data to determine whether the liner life can be safely extended.

Read more about the solution and outcome...

Increasing revenues by reducing shutdown time, improving safety 

Loss of revenue due to extended length of inspection shutdowns on a greenfield site. This site was concerned that the lack of operating experience with their new mill would mean significant downtime for inspections in the first two years while they gained this experience. The conditions in the mill are hot and humid with an extended period required for cool down.

Read more about the solution and outcome... 

Remote inspection – improve safety, reduce risk of catastrophic failure 

Confined space entry procedures for this mill require 12 hours because of the toxic nature of the gases produced. Downtime is very expensive because of the high value of the concentrate processed and is valued at more than $100,000 per hour. The mill is small (2 metres in diameter) and access is limited for manual inspection. Actual physical inspections inside the mill are infrequent.

Read more about the solution and outcome... 

Extending liner life, reducing wastage 

Liner service life needs to be extended. The lack of confidence associated with current methods of collecting thickness data and predicting when liners need to be changed out leads to less than optimum liner life. Clients want to extend shutdown cycles from 12 weeks to 14 weeks meaning that one shutdown is saved in a two year period. 

Read more about the solution and outcome...

Liner design optimization for production 

This site has suffered from declining production levels due to changes in the nature of the feed to one of a pair of SAG mills with one mill consistently performing at a 10% to 20% higher production level.  Although site personnel know that the current liner design in this mill is no longer optimal, little information is available on the basis of the current design, whether it actually improved performance when it was installed and how it can now be improved. With the current liner measurements, taken manually at a very limited number of locations, comprehensive and reliable information is not available.

Without more detailed information on how the liners are actually performing, the risks associated with a redesign program are unacceptably high.

Read more about the solution and outcome... 

Liner redesign for improved wear performance 

Liner design is often an inherited factor which has remained unchanged despite changing conditions over time. Obtaining approval for design changes is often difficult because it is hard to gather and to represent a clear picture of what is occurring inside the mill and how these problems might be solved.

Read more about the solution and outcome...

Detection of lifting liners 

Ingress and build up of slurry behind liners is a problem that is extremely difficult to identify. UTG measurements will provide the thickness of the liner at that point but will not show that the liner has moved outwards. This type of movement can overload bolts leading to failure. 

Read more about the solution and outcome...

Mill charge control 

Accurate measurements are required on ball charge levels and available mill volume to ensure the % of ball filling is constant and at the optimum level. If this is not done regularly and the ball addition rate adjusted then the charge level will rise or fall over time. 

Read more about the solution and outcome...

New mill management 

New mills installed on a new site bring a unique set of challenges.  Even though laboratory work has usually been done to characterize ore types, work indexes etc, the performance of the mill is a large unknown and can significantly limit mine production until sufficient working knowledge has been gained by the operators. Sometimes a liner redesign is required to address unsuspected problems.

In these situations, lack of reliable, accurate and complete data can severely compromise efforts to improve the performance of the mill.

Read more about the solution and outcome... 

Liner life cycle synchronization 

In many existing mills, liner lives are not very well synchronized so that extra shutdowns have to be carried out for a relatively small amount of relining. In a new mill synchronizing liner lives is impossible because the wearing characteristics are unknown.

Read more about the solution and outcome...