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FLSmidth has received an order for its BulkExpert™ digital solution from a customer in Brazil. The solution will fully automate the stockyard operation of two large iron ore shipping export terminals in the south of the country
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BulkExpert is a digital solution that allows for the unmanned, fully automated and optimised movement of material handling equipment in dry bulk terminals. It does this by using a 3D laser scanning system, RTK-GPS technologies and state-of-the-art control software that processes proprietary algorithms to enable fully autonomous operation
The BulkExpert order comprises a core digital solution and advanced automation for three stockyard machines at one port and eight stockyard machines at the other (including standalone and combined stackers and bucket wheel (BW) reclaimers)
“We are delighted to receive this repeat order for the BulkExpert as it is a clear indication of the customer’s satisfaction with the current BulkExpert solution at their terminal stockyard in South East Asia, which has been operational for five years,” commented Mikko Tepponen, CDO at FLSmidth. “The order is a clear vote of confidence for FLSmidth’s work during the feasibility stage and for our focus on high-performing, productivity-providing digital solutions.”
“As this was a complex and key project for the customer, we worked especially closely and comprehensively with them to ensure perfect alignment on scheduling and implementation. This work will mean an increase in productivity without loss of production due to downtime,” commented Ole Knudsen, Head of Digital Global Product Line Management at FLSmidth
FLSmidth says the solution will deliver several clear benefits to the customer, including higher throughput, greater efficiency and increased guaranteed performance. Extended machine life and reduced maintenance can also be expected due to lower stress on the machinery
In late 2017, Hatch was engaged to conduct a Mine to Process Optimization project for a large iron ore operation. The operation consists of three iron ore mines feeding seven processing lines contained within three plants. The operation also includes hematite recovery and a pelletizing plant. The processing lines have three different flowsheets and include some different applications of comminution equipment compared to many iron ore operations, such as dry AG milling and an HPGR in regrind duty. The objective of the Mine to Process Optimization project was to develop integrated mining and processing strategies to increase production and improve the quality of the pellet plant feed while minimizing costs. The operation aimed to increase concentrate production from 14Mt/y to over 17Mt/y
Hatch conducted and supervised detailed mine and process plant audits, full surveys with sampling of the plants, ore characterization testing, data collection, mathematical modeling, simulations and integrated analysis and recommendations for optimization of the three active mines and all processing lines. The Hatch blast fragmentation model, process models, energy/power-based models, extensive database and industrial experience were used to develop, calibrate and integrate the site-specific models for blasting, comminution and magnetic separation, which included some interesting challenges with dry AG milling and HPGR in regrind application
Numerous opportunities were identified to increase production and improve the quality of pellet feed with the existing equipment. Several changes in operating strategy were recommended including increasing and better distributing blasting energy according to ore characteristics, tightening crusher gaps and screen apertures where appropriate, changing mill internals and operating conditions, HPGR product recycle and cobbing, redirecting magnetic separation streams, etc. Where these improvements would be insufficient to meet the specified production targets, expansion options were proposed and evaluated
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