Stein Hermansen, operator at Norwegian Edelsplitt’s new fine crushing plant, checks the computer screen after the morning’s maintenance routine. Nothing new. He scratches his beard, boils his second pot of coffee for the day and opens the day’s local newspaper. If something were to happen, he gets a notification on the screen.
Challenge
The aim of the crushing plant is to achieve continuous production with the lowest cost per tonne. To achieve this, the plant must be self-driving. The challenge with self-driving equipment is that it should never stop. Crushers must not run empty, feeders must run smoothly and sieves must give the conveyors the correct fractions at all times.
Norwegian Edelsplitt ønsket et verk som gav lav kost per tonn. Da tok vi et steg tilbake og kartla hele området, sprengte bort et halvt fjell, og designet et verk som er selvkjørende.
Se prosessen steg for steg i bildekarusell.
Solution
In order for the plant not to stop, machines along the entire production line must be adjusted with small variations. It already starts with the feeder from the buffer storage. To meet the correct production target, the plant had to have two crushers. The customer chose two pieces of Sandvik CH 430.
To ensure that both produce evenly, we made a silo above each crusher, with sensors that measure the level. If there is a risk of one of the crushers running out, the Skako feeder increases the pace from the buffer storage.
If one of the silos begins to fill, there is a bridge between them, which means that crushed stone flows into the other. If both silos start to get full, the supply from the buffer storage is throttled.
All this happens automatically, and requires minimal personnel in the plant.
Måler hastighet
Sensorer passer på at transportbåndet går med riktig hastighet. Avvik kan bety at båndet slurer, for tung pålast eller overbelastning på motor.
Kontrollsenter
Container hvor en operatør har full oversikt. Ved feilmelding kan han overstyre verket.
Måler nivået
Hvis sikta begynner å bli full, gir en digital vakt beskjed til systemet, og transportbåndet inn stopper.
Fullmelder i silo
Ved riktig nivå i silo, får anlegget beskjed om å øke utlasting til bufferlager.
Automatisk påmating
Inne i kulvert kommuniserer Skako materen med resten av anlegget. Den justerer påmating løpende.
Sensors for self-propelled operation
- Full notifiers in silos
- Speedometer in conveyor
- Level guard in sight
- Vibration guard in sight
- Volume weight on conveyor
Noise and dust reduction
Living near crushed stone is a known problem for many. It is then important to reduce dust and noise from the work in order to be able to live side by side with as little friction as possible.
To reduce the noise level, we built insulated sandwich panels around both Sandvik crushers and Wima screens. In addition, we installed a tailor-made system for dust suppression from the specialist Sismark dust solutions.
To be considerate of neighbours, we built all crushers and sieves into insulated sandwich walls. These dampen noise and prevent dust from escaping into the external environment. In addition, a dust suppression system has been installed.
Data will change the industry
Sensors in production continuously send out data. If we collect the data, we can use it to estimate trends, see how long spare parts last and much more. This will provide far more efficient production, and is already used in a number of industries.
Click the button below to see what big role “big data” will play in the future operation of crushing plants, mines and mineral extraction.