Study shows that technology increases productivity in mining

The mining industry is constantly seeking improvements that will increase productivity and make the plant more efficient. It also focuses on reducing costs, including better use of equipment and greater longevity of wear and replacement parts.

Therefore, today we will present a case study carried out by the Máquinas Furlan team in a quarry. There were 4 possibilities for improvements offered to the company. The use of the AggFlow software allowed leaps in productivity, reaching 91%, compared to 55% in the scenario found in the diagnosis.

It also brought the possibility of generating new products.

Check it out.

Discover the 3 main points of a mining improvement project

This content is a continuation of the post we made last week, regarding the AggFlow software. This technological tool speeds up decision-making in mining.

Review this content here .

However, it is important that quarry and mining managers know in practice how AggFlow works.

First of all, it is important to emphasize that there are 3 main points in this type of project. They are:

1. Mass balance

It is the principle of conservation of mass in which a mining system tends towards equilibrium. At this point, the most relevant parameters for those seeking improvements involve data such as instantaneous production, granulometry, concentration and ore content in the rock.

2. Technology helping decision making

In this case, the AggFlow software, after receiving the plant data, indicated installation components. The simulation of instantaneous capacity and the identification of possible bottlenecks serve to evaluate the plant's behavior.

It also compares the impact of different machines and installations, based on the current scenario. With simulation, engineers can change parameters, optimizing the plant.

3. Bottlenecks

This is one of the main challenges in the industrial sector. A bottleneck represents flow at its most critical point. An undersized or overloaded machine stops production, compromising results.

In the case studied, Furlan engineers found 3 main bottlenecks. The vibrating feeder was working without a grate. The primary crushing was very focused on the production of fines. The secondary crushing, in turn, showed low efficiency.

The cone crusher's efficiency was around 55%, a result far below the usual. The final products were stone 1, gravel and sand.

This cone efficiency percentage is considered low. Therefore, in studies, engineers present alternatives to improve indicators.

Improvements: increase in productivity and greater number of final products

The Furlan team entered the data from this diagnosis into AggFlow. The software presented four proposals for improvements to the line. Find out more below.

. Suggestion 1 – Capacity increases by 70% and generates more final products

The proposal included a vibrating feeder working with a 4-inch grate. The running spout in the system would be up to 45 mm – a parameter adopted in all the suggestions below. The layout in this suggestion would receive a modular screen model PVM800240, with 3 decks.

The plant's production would increase to 230 tons/hour, an increase of 70% compared to the current scenario. The cone's efficiency would reach 95%. The final products would be: running spout, stones 1 and 2, gravel and sand.

. Suggestion 2 – Stack format and a second sieve would bring productivity

In this simulation, the 4'' grid feeder would operate in a "pile" fashion. There is also something new in the equipment. The modular screen would be supported by a PVA600240 2-deck vibrating screen.

Vibrating screens bring capacity and efficiency to a quarry.

Production would increase by approximately 90%, reaching 250 tons/hour of running sand, stones 1 and 2, gravel and dust. Fewer belt conveyors would be needed. Cone efficiency would reach 91%.

. Suggestion 3 – Impact crusher is incorporated; beneficiation generates sand

In this simulation, the feeder with grid and forming pile was maintained, as well as the two sieves indicated in the previous suggestion.

The new feature is the installation of the vertical impact crusher (Rocha-Rocha) from the OM100 line.

The cone efficiency jumps to 84%. The plant would generate 230 tons/hour, an increase of 70%. The generation of a robust quantity of sand would be possible, in addition to running sand, stone 1 and 2 and gravel.

. Suggestion 4 – Gaining strength with the high frequency sieve

AggFlow also tested a high-frequency screen in the layout, model PVAF400190, with two decks. The modular and vibrating screens from suggestion 3 were maintained, as well as the grate feeder; spout up to 45 mm; and the OM100 crusher.

Production jumps to 250 t/h, with the cone crusher reaching 91% efficiency. The final products include coarse, medium and fine sand, running sand, gravel and stone 1 and 2.

The importance of choosing a mining machinery supplier

The simulations mentioned here take into account the specific characteristics of the quarry. The analysis needs to be customized, including the desired productivity, the rock to be processed and the desired end products.

It is also important to look for a supplier of mining machinery and parts with market experience and who understands the client's investment capacity. Máquinas Furlan has over 60 years of experience in projects and has a catalog with around 150 pieces of equipment manufactured in-house for ore processing.

The machines mentioned in the four improvement proposals are included in this catalog, which speeds up the decision-making process for mining companies.

So, schedule a meeting with our team and find out how Furlan can offer improvements for your plant. Click here and send a message.