Screens and shakers are essential equipment for keeping mining operations running, yet the average facility suffers up to 30 failures per year for this asset type.
Pumps are the key to maintaining throughput in a mining operation, but they frequently fail due to the harsh conditions in which they operate and the difficulty of monitoring their health.
Baghouse fans keep production areas free of airborne fine particulate matter that can threaten the health and safety of your employees. The average baghouse fan fails up to 10 times per year.
Frac sand mining operations rely on drying kilns to complete the critical final step in the production of sands used in paving. The trunnion bearings that keep them moving have to work constantly, increasing their rate of failure.
Jaw crushers and mills are used to break mine products into standard discharge sizes. Naturally, crushing ore causes high levels of wear and tear on these assets, and they’re difficult and often unsafe to monitor.
Bearing defects, clutch failures, and bent pulleys all contribute to conveyor system failures which can bring production to a standstill. Belt conveyor failures can also threaten worker health and safety.
Induced draft fans are crucial to the mining industry. Failures on these assets can be costly as it can take a considerable amount of manpower to replace. Unexpected downtime from an induced draft air fan can get expensive, very fast.
Gearbox failure is one of the most common reasons for malfunctions and production loss. In the mining industry, gearbox failures can lead to unplanned downtime, lost production and costly damage to connected equipment.
As an ecosystem partner, we empower you with both data ownership and unmatched flexibility. Your data belongs to you. Giving you complete control.
“Improving reliability, that’s what we are after. It improves everyone’s lives at work as the reliability goes up.”
Larry Kessler
Director of Operations Support
Pennsy Supply
The mining industry is notorious for heavy duty equipment and harsh operating conditions. This is often a recipe for headaches when it comes to machine health and reliability.
In environments with such harsh conditions, most predictive technologies fail. Perhaps the most obvious example of this are the vibrating screens found in mining operations around the globe. This machine class is designed to vibrate at high levels to allow for sifting and sorting to achieve the desired separation of material sizes. As one could imagine, this type of machine function has traditionally made vibration analysis nearly impossible. Despite these realities, KCF Technologies is uniquely positioned to monitor and identify developing failure modes on vibrating screens thanks to a few key components.
Mining equipment is notoriously difficult to monitor. Time- or route-based data collection can’t accurately capture changes in machine health since operating conditions can vary wildly from day to day or even hour to hour. You can’t predict when machines will fail if you’re working with bad, incomplete data.
SMARTdiagnostics, our comprehensive machine health platform, allows individual monitoring points on your assets to wirelessly and continuously transmit machine health data to a central database. Its advanced analytics capabilities get to the root cause of machine health issues. CMMS integration and personalized dashboards drive meaningful actions to keep your mine operating at its peak.
Equipment and maintenance costs account for up to half of a typical mine’s operational expenditures, so any efficiency gains in the area of machine health represent a significant boost to your bottom line. Knowing when downtime should be scheduled to keep assets running at their best—rather than constantly reacting to disruptive equipment failures—keeps throughput high and makes better use of labor resources.
The typical mining operation spends up to 50% of its budget on equipment and maintenance costs.
Equipment failures don’t just impact productivity. Mining equipment can fail catastrophically, posing a threat to the health and safety of your workers. Even routine monitoring and maintenance can lead to workplace injuries, since mining assets are often difficult to reach and operate in hostile environments. Continuous remote monitoring keeps your maintenance team safer and gives them more time to focus on reliability. Plus, the ability to forecast machine failure ensures that no one will be in the wrong place at the wrong time.
The ability to forecast machine failure ensures no one will be in the wrong place at the wrong time.
Gain access to a team of engineers and reliability experts with unparalleled experience in mining-specific environments, asset health monitoring, root cause analysis, and problem-solving.
Our platform was designed specifically for manufacturers facing the toughest machine health monitoring challenges—ones that traditional solutions can’t tackle. We’ll help you prevent unplanned downtime and increase productivity, safety, and revenue.
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