Scanalyse is a company which has benefited strongly from ...



CRCSI Newsletter Article 2007

Scanalyse Pty Ltd: 3D Laser Scanning for the Mining Industry

Summary

New laser scanning technology is being used by a start up company Scanalyse Pty Ltd to improve the efficiency of global minerals resource processing, saving money and reducing greenhouse gas (GHG) production.

“MillMapper” is the commercial application of CRCSI research by Curtin University. It is a three dimensional scanning and modelling service to the global minerals processing industry that reduces maintenance costs, increases productivity, improves safety and offers greenhouse savings in the energy intensive milling industry.

Background

In minerals processing, large rocks are crushed into progressively smaller pieces and finally into powder. This comminution process is carried out in a series of huge crushing then grinding mills, one of which is shown in Fig 1.

The rotation of a mill causes the ore pieces to tumble, grinding the ore. Most types of grinding mills have steel balls which assist in the grinding.

Inside the cylindrical mill is a replaceable lining designed for the specific conditions of mill operation. Liners protect the shell of the mill from damage and erosion and aid grinding performance. Naturally, liners wear out. While good liner profiles can enhance milling efficiency, excessively worn liners decrease milling performance and energy efficiency. And if they wear through or fail a catastrophic and expensive shut down occurs.

Mills run 24 hours a day, 7 days a week. Replacing a mill liner requires significant mill downtime which is costly (downtime for a single average sized mill can cost a company tens of thousands of US$ per hour). Also, worn liners can significantly degrade the efficiency of a mill. So assessing the state of mill liner wear is of importance to a mill operator.

What was achieved?

The research of the CRCSI laser scanner team, based at Curtin University, has been developed in conjunction with Scanalyse Pty Ltd into an innovative software product and service called MillMapper.

MillMapper provides a three dimensional computer model of the interior of the mill, automatically extracting features and profiles from the millions of data points captured by laser beam. The software compares the scan with a CAD model of the mill and provides a series of high tech but user-friendly reports. The model it generates can also be interrogated and manipulated to provide sophisticated analyses.

The model allows mill operators to extend the life of liners; replace only those liners that need replacing; increase production efficiency; reduce shutdown time; operate more safely with no personnel required to enter the mills.

The technology is the core Intellectual Property of Scanalyse Pty Ltd which is commercialising the product. Scanalyse is working with the CRCSI team to refine MillMapper and to develop other laser scanning applications in the resource industry.

What was innovative?

The key innovation features of the technology are

• the use of laser scanning devices inside mills to accurately map the internal contours and wear patterns. The previous method of collecting wear data was to stop the mill and manually measure a few points with an ultrasonic thickness gauge – a slow process that is dangerous, unreliable and inaccurate with a limited amount of data. MillMapper collects millions of data points within minutes of the scanner being lowered into the mill

• smart software particularly the automatic feature extraction to predict wear patterns and potential catastrophic failure sites.

• a methodology of processing the raw data without fixed registration points to enable calculation of liner thickness and consequently wear

• proprietary techniques for extracting shape and size data of various internal mill components.

PCT patent protection has been filed with a priority date of April 2005, claiming key aspects of the methodology that will place major technical barriers in the way of future competitors. Separate filings have been made in relevant countries not party to the PCT.

Ongoing CRCSI research with Scanalyse is being conducted to continually strengthen the patent portfolio and to explore new applications of laser scanning in the mining industry.

What was the impact ?

MillMapper is industry proven and has been accepted enthusiastically by mill operators. It is being used regularly to monitor mills by companies such as Alcoa, KCGM and BHPBilliton. It has been used in over 40 mills on 13 different minesites and Scanalyse has established a strong sales pipeline. Initial export sales commenced to Indonesia in December 2006 and will be followed by sales into PNG, Canada, Peru and Chile in 2007.

Scanalyse sales currently support five staff, with plans for expansion in FY 2008 to a turnover of $1.5M per annum having achieved compound growth of over 50% annually since inception.

Safety

• Improved safety – the laser scanner is lowered into the mill so in contrast to current methods no operators have to enter the very hot, dirty, and dangerous interior of the mill [incl dust in the air, and temporarily lodged debris falling from the mill ‘ceiling’].

Maintenance

• Extending mill wear liner life - Typical cost to reline a large mill is $1M to $2M per year. A 10% increase in liner life will reduce costs by $100,000 to $200,000

• Reducing shutdown time for relining - Extending liner life means fewer downtime hours.

Estimates with current clients puts downtime costs at some $50,000 per hour

• Reducing shutdown time for inspection – A scan takes only 5 minutes and the mill does

not have to be isolated for confined space entry.

• Failure prevention - Early detection of internal flaws and damage to the liners is made much easier with MillMapper, helping to prevent catastrophic failures

Process Optimisation

• Optimising throughput can be achieved by monitoring liner profile shape throughout life and modifying to improve efficiency. A 5% increase in throughput will realize extra revenue of $17 million in a typical mill

• Better control over mill performance by automatic and accurate calculation of ball charge volume, grate hole size, ball size and shape, and ball to ore ratio increases production and revenue. These have great impact on efficiency and economics, but in the past have been too difficult to monitor and measure.

Environment

• These efficiency based economic savings bring major environmental benefit through reducing electricity use, thereby reducing GHG production by millions of tonnes

Key elements to the approach

MillMapper enables precise measurement of the internal surfaces of AG/SAG grinding mills, using a high precision laser scanner, and extracts thickness, wear rate, shape and size data by patented data processing techniques.

Fig 2: Raw laser scan data capture Fig 3: Details from Fig. 2

The 3D data collected is processed and converted to thickness measurements, which are displayed visually by the software. Figure 4 below shows an example of shell and feed end liners where the colour is related to a thickness scale. The red portion highlighted is showing minimal thickness and in fact relates to a missing endplate.

This is a powerful monitoring tool in the hands of mill operators who are able to carry out a detailed “virtual” examination of all parts of the mill. They are provided with these processed data files for review along with sophisticated reports documenting wear rates and other critical maintenance parameters.

Fig 4 Mill liner model

A technology and product roadmap has been developed which will see further functions added to MillMapper. Also, new 3D laser scanning products are being developed by the researchers and Scanalyse and leading edge customers with the first one due for release in early 2008.

Adoption

The outcome of the R&D has been taken up through a start up company called Scanalyse Pty Ltd. The company was formed through seed funding from Curtin University and CRCSI.

It is based at WA’s Bentley Technology Park, and retains strong links with CRCSI and Curtin University. The inventors are significant shareholders and are represented on the Board as an interim measure. CUT has a Board seat, and the CRCSI is assisting in taking the next commercialisation steps, viz seeking investment funds and a senior powerful Board.

The technology has been taken up enthusiastically by Australian minesites and Scanalyse is now taking this technology overseas. Trials are being conducted in North and South America in mid 2007 with trials in South Africa scheduled for later in the year.

An aggressive expansion program is planned for the company within its confidential investment proposal. Sales are projected to reach $10 million per annum by 2010.

Need for the CRC

The CRCSI has been an essential ingredient in providing a synergistic framework, including

• funding the research and development and thereby in building on the IP generated by the Curtin University team

• supporting the commercialisation endeavours now being pursued through Scanalyse Pty Ltd the start up company. This includes financial support for development but also advice and funds and using the international networks of contacts

• funding of research that will feed into the company’s development through a tight collaboration to carry the relationship forward

Scanalyse Pty Ltd has joined the CRCSI SME consortium known as 43 Pty Ltd, or “43pl”. The CRCSI has an equity relationship with Scanalyse.

Other pictures …………………………………………………………………………….

Fig 1 large grinding mill 3D laser scan data point cloud

Point cloud transformed to liner thickness

End plate view showing high detail

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