Case Study : Coal Mine Tailings Line
DATA & ANALYTICS
“What we ’ ve seen during the pandemic is that miners have realised they need to embrace the digitisation journey ”
JOE CARR MINNING INNOVATION DIRECTOR , AXORA
Case Study : Coal Mine Tailings Line
2Censor – IIoT Solutions
2Censor offers remote monitoring and predictive maintenance for plant assets to guard against erosion and provide wear abrasion testing .
Business Challenge :
• Coal mine product reject pipeline
• 2 x 5km x280mm
• PN25 HDPE in 20 m spools
• Pipe spools lasting 6 months
• High risk of environment incident and unplanned plant shutdown
Goals :
• Reduce supply spend
• Reduce environmental risk
• Reduce safety risk / inspection cost
• Reduce unplanned outage
Solution :
• Probes installed in each pipe quadrant – at known wear areas 300mm back from flange
• Software aligned with 3x rotation alerts – 4th to notify replacement with 8 weeks lead time
Investment :
• $ 186,000 / year
Returns :
• Pipe life extended via intelligent rotation from 6 months to 2 years = $ 1.5mn saving on supplies
• Unplanned outage reduced to zero .
• Cost saving compared to previous year = $ 1.2m
• Cost saving associated with increased safety and zero environmental incidents not quantified ROI > 1400 % Payback < 4 weeks
90 May 2021