23 January 2019Case Studies
Overview
• Coal chute liner plates
• Used in primary stage crushing
• Assessment from new to obsolescence
Analysis strategy
• 6 weekly interval scans
• 12 chute scans per day
• Report deliverables blue/green/red map
In conjunction with the customer, 7D Team developed the process, procedure and methodology to provide continuous wear monitoring statistical data that could be used to asses and predict wear characteristics, with a view to prolonging the life of the chute liners.
The report format process was developed into an easy to read visual report. An indicator format (blue/green/red map) was automatically generated, so that in many cases, the reports were available in HTML format before leaving site each day.
Each report has been tailored so that subsequent scanned data of the same liner can be overlaid, showing wear characteristics over time. Report accuracy is within 0.02 (or 20 microns).
‘, ‘Wear analysis to extend life of coal chute liners’, ‘In conjunction with the customer, 7D Team developed the process, procedure and methodology to provide continuous wear monitoring statistical data that could be used to asses and predict wear characteristics, with a view to prolonging the life of the chute liners.’, ‘publish’, ‘closed’, ‘closed’, ”, ‘wear-analysis-to-extend-life-of-coal-chute-liners’, ”, ”, ‘2024-01-23 11:51:29’, ‘2024-01-23 03:51:29’, ”, 0, ‘http://www.7dteam.com/?p=1227’, 0, ‘post’, ”, 0), (1506, 1, ‘2020-08-10 14:31:28’, ‘2020-08-10 06:31:28’, ‘
A refinery operating in Western Australia recently approached us to improve and redesign an under performing old pump, as it over its years of operation, process needs had changed. To achieve the desired outcome, very close collaboration was needed between our firms.
We accepted the challenge and re-engineered components to re-rate the existing pump, optimising it suit the site specific operating conditions. We then produced it using advanced and modern manufacturing techniques.
The end result was an astounding 20% efficiency increase: a world leading efficiency for a pump of this size. Staggeringly, the NPSHR was also reduced, using modern techniques, extending rather than reducing the allowable operating region.
Andrew Collins, Executive Chairman of 7D Team, said:
“We have been working intensively on this design, so it is great to see the hard work pay off with huge benefits not only for our customer but it also paves the way for more environmentally friendly designs in the future”
The pumps are estimated to save the refinery $2,000,000 p.a. in electricity, improved reliability, and performance that optimises process flow needs. The payback period for the project has been estimated by the refinery engineers at just 3 weeks!
Pumps contribute to a massive 8% of the world’s power usage, but are often overlooked when reducing environmental impacts.
Unlike imported electric motors, pumps have no minimum efficiency requirement and the industry is plagued by designs that are low cost, but extremely energy inefficient.
Andrew said they hope to replicate the efficiency savings across a wider range of pumps by collaborating with others in the pump industry.
“We hope to work with industry partners and the Australian government to reduce the carbon footprint in the mining industry”
“On this basis, we are incredibly thankful to the large socially responsible US owned refineries operating in our region. They are actively looking to reduce their carbon footprint, on and off US soil, whilst supporting design and manufacturing innovation within the regions they operate. By seeking partners to solve a long term problem, all were rewarded”
For more information, contact info@7dteam.com
