The program, designed and developed by the customer service
division of FLSmidth Minerals, has been put in place to optimize output and
extend the operating life of Wemco cells.
With visual inspection techniques, the robust design of the
cells could give the impression they are operating effectively, even when parts
are worn. Additionally, the key components for the cells deliver relatively
long service lives so it could become easy for operational and maintenance staff
to neglect regular maintenance checks.
“These cells are built to last, but they are mechanical and key
wear parts do need replacing,” said Stephen O’Connell, maintenance project
engineer at FLSmidth Minerals. “Some of the internal components do offer
short-term options – for example, the rotor can be inverted and/or reversed –
but ultimately component replacement is the best decision for continued optimum
yield.”
O’Connell says knowing when to act can be established
relatively easily and the results of three straightforward tests, as part of a
regular maintenance program, can determine decreases in cell performance. The
test regime includes analysis of metallurgical performance through sampling, tracking
of the cell’s power consumption, and the physical appearance of the residue on
the cell floor when empty.
“Any one of these tests will give a good indication of a
cell’s operational performance,” said Stephen O’Connell. “With this research on
hand, the next step is an analysis of actual and potential lost yield against
the cost of the upgrade program.”
The upgrade program includes the replacement of a cell’s
rotor, collar, disperser and disperser hood – universally acknowledged as key
wear parts in float cells. Also included is the relocation of the air intake
valve, from the bottom of the tank to a location adjacent to the drive motor,
to improve access for visual inspection and periodic maintenance.
The program has been designed to minimize cell down time and
all components can be quickly fitted on site in conjunction with an existing
maintenance schedule.
The replacement/upgrade program is proving its worth in coal
processing plants. Independent testing of a completed job in the Hunter Valley
recorded an 8% increase in yield within three months of the cells coming back
on line. Two trials currently underway, also in coal processing plants, are
showing similar increases in yield.
“Coal processors are getting good results from their
upgraded cells,” O’Connell said. “Laboratory testing and modeling also
indicates that hard rock processors can expect similar yield increases from
upgraded cells.
For further information, FLSmidth Minerals; phone 02 4320
4700/ email: infoaustralia@flsmidth.com