Outotec®-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.
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.
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.
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.
|Tracked cross-sectional profiles
||Tracked longitudinal profiles
The 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.