Crushing connectivity

Growing populations, dwindling resources and escalating ecological problems pose an enormous challenge for humankind: more must be done with less. Necessary materials must be extracted and processed cost-effectively and sustainably, with lower impact and a smaller carbon footprint.

Digitalization creates a new dimension on top of conventional business processes. We can readily connect machinery and collect data on an unprecedented scale. Tools are there, but the question is, who has the smartest solutions to utilize the astounding amount of data that we are now capable of collecting and the knowledge to process it into tangible benefits?

From an equipment supplier’s point of view, this creates demand for business models and aftermarket services that truly help operators to overcome the challenges mentioned above. More and more industry professionals think less in terms of what equipment do I need to buy, and more in terms of what capability do I need and how can I get it to meet my operational and business targets, as well as sustainability targets

This means the capability to introduce more sensors, measure more and more accurately, creating reports to give a more accurate picture of what is happening inside the crushing process so that it can be improved.

“What we are doing here is that we are actually sending the data that is generated by the cone crushers to a cloud solution, My Sandvik, for our customers to be able to access valuable reports from the data generated by their connected Sandvik crusher fleet,” says Martin Johansson, product line manager for compression crushers at Sandvik Mining and Rock Technology.

“We have now launched a platform for the digital solutions of today but also for tomorrow,” Johansson says. “Basically, we’re taking the first steps for the future to come: more sensors, more cameras and more data. This will enable business decisions based on facts instead of guesswork.”

The Sandvik 800i series of cone crushers, which reached its full scope with the latest expansion into eight crushers in September 2019, shares the same design philosophy, with the main focus on excellent productivity and reliability. It collects under one umbrella all of Sandvik Mining and Rock Technology’s flagship cone crushers to build a unified mechanical platform for the automation and connectivity solutions, ranging from 61 to 1,837 tonnes (67 to 2,025 short tons) per hour in design capacity and from 211 to 428 millimetres (8.3 to 16.9 inches) in maximum feed size.

Mechanically, the Sandvik 800i crushers stand out with their toughened-up main shaft and top/bottom shells. The resulting strength increase means improved reliability, better availability and a low risk of critical failure.

Details such as bolted top and bottom shell liners, instead of welded ones, enables up to 90 percent faster liner change. An over-pressure system prevents ingress of dust for increased reliability, and the standard offline filter keeps oil cleaner, extending the oil life by up to five times. Eliminating plastic backing material prevents the exposure of maintenance personnel to harmful substances during liner replacement work.

Lessons can more easily be learned from fault situations, and problems can even be predicted before they have an impact on the operations.

The Mantos Blancos maintenance crews have significantly improved their predictive maintenance results, and the mine management can make better-informed, fact-based decisions in the sulphide processing circuit.

“We look forward to offering these substantial benefits for all crushing plant operators throughout the world,” Johansson says.