Mining

Mining was one of the first established industries in the world. Despite so many years of development, there is always a need to develop new technologies for common problems.
Thermography immediately entered the condition monitoring, due to the criticality of the facilities equipment and machines. However, certain processes began to use thermographic monitoring successfully for optimization, such as electrolysis. Similarly, fire prevention at the mine greatly benefited from the early warnings delivered by fixed cameras, also highlighting the gas detection performed by OGI cameras.

Applications

A critical process in mining refineries is electrolysis. This phenomenon, so common in our daily lives (for example, in remote control batteries, in cars), performs the essential task of removing impurities from the mineral. Impurities that are not necessarily disposable, for example, silver is removed from the mineral in this process as an impurity.
The most common problem here are short circuits, which are imperceptible to the eye while the process is being carried out, but when removing the anode or cathode, it will be possible to perceive that it contains many impurities. The short circuit produces a considerable amount of heat, which is easily perceived by a thermal imager.
The bcbElectrolyticIR is a system based on FLIR thermal imaging cameras with the purpose of detecting short circuits produced in the entire electrolytic bath area. With artificial vision tools and instrumentation engineering, it is possible to equip the plant with an efficient short location system and improve the action plan in the event of these events.

Applicable minerals:

  • Copper
  • Zinc
  • Silver
  •  Gold
  • Lead

Once the minerals are extracted, they need to be transported to the concentrator plant for the flotation, grinding and pumping processes. Large quantities of ore are transported minute after minute and a system failure would break this production chain. That crucial system is the conveyor belt system, commonly known as the conveyor overland.
Inspections on the conveyor are carried out with a certain periodicity, but not with the desired periodicity, since it is normal to inspect only during stoppages, which are very few. The indication of failure is difficult to find under these conditions.
Fortunately for the mining sector, there is already an inspection technology that does not require stopping the conveyor to inspect it: high-speed thermography. The FLIR cooled cameras integrated into the bcbMonitor 4.0 software enable a complete sweep on both sides of the conveyor and generate a highly reliable damage report from this.

Detects:
• Cracks
• Agglomerations
• Detachments
• Exposed and broken cables

Mining not only consists of extracting minerals from the earth but also employs physicochemical processes in order to separate or purify them. Substances are used that can be toxic to workers and sometimes due to more care being taken in handling them, leaks are present, unleashing from economic losses to poisoning or fires in the facilities.

Today’s most advanced gas detection technology is found in OGI (Optical Gas Imaging) cameras. FLIR Teledyne has today the most reliable infrared devices for this purpose and software tools such as the bcbGasScan help automate leak detection, providing functions such as triggering alerts by plant zones, quantifying emissions and communicating with others. devices of the risk prevention system in the plant.

Detectable gases:

  • Hydrocarbons
  • CO
  • CO2
  • Ammonia
  • Ethylene
  • Refrigerants

The life of a mine is not usually very long, but it does work continuously and without interruptions in it. The stoppages represent a huge loss not only for the mining company but for the entire supply chain, with mining being one of the primary activities. Thermography has always been part of predictive maintenance strategies, however, there are equipment and machines that require continuous monitoring.
The bcbMonitor 4.0 system works in conjunction with FLIR Teledyne cameras such as the Ax8, A70 / A50 and Axxx series. This results in an effective method of monitoring failures or trends that point towards one of them. The information of each of the cameras in the plant can be consulted in real time, as well as the statistics and an alarm system can be established in the event of any situation that requires immediate attention from the personnel.

Inspectable items:

  • Buses
  • Bearings
  • Thermally insulated surfaces
  • Refracting Material
  • Tensioning elements
  • Engines

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