Metso provides metrics that are helping quarries reduce unplanned downtime, improve productivity and optimise performance.
Technology is enabling quarry managers to view data in real-time, allowing them to make informed decisions to enhance business operations.
These data can come in many forms, from metrics to maintenance tools. Original equipment manufacturers (OEM), including the likes of Metso, provide fit-for-purpose tools to support key quarry functions like crusher maintenance, aggregates production and screen performance.
Metso business development manager John O’Reilly and Metso product manager for HP Cones Ilkka Somero spoke to Quarry about the company’s range of metrics and digital tools to support construction material producers.
Crusher collection
At the heart of any quarry is its crusher. The quarry’s production levels are defined by its crusher’s performance, and without crushing at optimal levels, project deadlines suffer.
That is why Metso created a suite of digital tools to track crusher maintenance so that maintenance could be carried out safely without inhibiting production.
“Safety is a key factor within our business today and a top priority for us. It is important to find new ways that enable employees to work in a safer zone all the time. Our maintenance platform for jaw crushers is a good example. This equipment improves working conditions and safety,” Somero said.
“Before the launch of the maintenance platforms for the Metso Nordberg C Series jaw crushers, for example, no industrial and commercial solution was available. And the practices in the field varied a lot: some of them were difficult for the maintenance crew and some were not safe. So, there was a clear demand for a professional solution.
“Our approach in the development of the maintenance platforms was to combine safety and ease of use. And I can truly say that we succeeded well.”
The maintenance platform for the Metso Nordberg C Series jaw crushers is available in both one-piece and two-piece jaw die configurations. The platform fits into the crusher cavity and supports the jaw dies in place, ensuring that they cannot drop. It is designed to be easy to adjust and lightweight, allowing just one person to lift them using the equipped handrails, which reduces the time spent within the crusher cavity.
“Many customers in the mining and aggregate industries have identified working in the jaw crusher cavity as a potential safety concern,” Somero said.
“Every now and then, the people doing service and maintenance on the jaw crusher must enter the jaw crusher cavity. How often that happens depends on many things, such as the abrasiveness of the rock or ore to be processed by the crusher. The reality is that the need to enter the crusher cavity cannot be avoided.
“The maintenance platform is a small investment that significantly improves safety and ergonomics.”
Metrics monitored
Two of Metso’s most popular metrics platforms are for aggregate production and screen monitoring.
Metso has helped customers use screen monitoring metrics to increase uptime and reduce spare parts and screen media consumption. These savings have flow-on effects across the business, including improved safety due to less unplanned maintenance and higher throughput rates, and the screen’s performance is optimised.
“Think of metrics for screen monitoring as a 24–7 guardian for the screen: it’s integral to reducing unplanned downtime and extending its lifespan. More importantly, it optimises screen performance to help perfect your overall process,” O’Reilly said.
Metso’s metrics monitoring provides a real-time analysis of the vibrating screen’s performance and bearing conditions. If the system detects an issue, it will alert the operators, controllers, and service professionals so they can perform the required maintenance.
Employees can also use this information when planning future maintenance breaks, as knowledge about past events like broken springs, incorrect run speed, or structural support can identify issues before they become a major expense.
“By collecting data in real-time, it is possible to get access to fault-finding recommendations and be able to quickly analyse trends,” O’Reilly said.
“This makes it easy to try different parameter settings in order to optimise the process according to your current conditions and targets. It will also have a positive effect on sustainability as optimally running the screen enables increased uptime and less consumption of media and spare parts. Using fewer parts translates to less waste ending up in a landfill.”
O’Reilly said Metso’s team would be able to train any quarry professional on how to use the screen media monitoring system for their business.
“Metrics for screens is designed for intuitive operation. An easy-to-read screen dashboard with OEM insights makes it possible to detect issues quickly. The integrated system delivers complete diagnostics, alarms, and history at a glance,” he said. “Modular sensors are wireless, self-powered, and easy to use. All components are engineered to be reliable, even in the toughest environments.”
All of Metso’s metric tools, including the screen media monitoring and metrics production tracker, are secure, cloud-based platforms. These metrics platforms are accessible through a single portal for ease of use.
This means that all of a quarry’s Metso aggregates fleet, including mobile, portable, and stationary crushers and screens, can be tracked easily 24–7 on web-enabled devices. Having access to this real-time data reduces the trouble-shooting process, which means increased uptime.
“High crusher availability is crucial in aggregate production. In the past, dealing with equipment breakdowns meant sending someone to the site to collect more information. This was time-consuming, created production delays, and increased your indirect costs,” O’Reilly said.
“Collecting and analysing this data increases your assets’ uptime, leading to higher production output and improved predictive and reactive maintenance.” •
For more information, visit metso.com
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