A client was manually crushing large lumps of a metallic material to a size suitable for feeding a grinding mill. This process was time consuming, labour intensive and dangerous.
- The process had a high risk of causing a serious hand injury.
- The process was difficult and time consuming.
- Rework volumes were high due to the size variability of the crushed product. The next stage mill was often blocked or restricted, resulting mill breakdown and delays in production.
- The equipment was clumsy and not designed for the task. This led to frequent overheating and equipment breakdown.
- The material itself was very hard, and difficult to break.
Identified the following:
- The input material was characterised in terms of size distribution and hardness.
- The input material specifications for the grinding process were defined.
- The process specification for the crushing process were defined.
- Equipment suppliers were contacted and a short list of possible equipment drawn up.
- Process trials were arranged at a number of equipment suppliers.
- Suitable equipment supplier was identified and equipment verified.
- Equipment specification reviewed and confirmed by all stakeholders.
- Review of siting, controls, procedures and hand-over plan completed and reviewed.
- Installation and commissioning of equipment.
- Hand over to operations.
- Significantly safer operation.
- Removed bottleneck.
- No rework required.
- All crushed product suitable for next operation.