Preparing bitumen ore from the mine for separation in the primary extraction facility is complex.
It requires crushing and sizing the ore to an optimal size for mixing with hot process water to form a bitumen slurry, which is then pumped the primary extraction plant. This process is extremely hard on mechanical rotating equipment including crushers, breakers, and sizers.
The equipment experiences extreme loading, impact forces, and other degradation, which effects the gearboxes and motors driving the equipment. Unplanned failures of the gear boxes and motors can result in huge production losses as well as safety concerns. There are many challenges inherent to diagnosing the actual health and condition of crushers. Large slow speed rollers and gearboxes impact loading and the harsh operational nature of the crushers makes collecting accurate and valid data very difficult. Any upsets on the crushers can have major impacts on production.
Utilizing Emerson's AMS technologies allows for stress wave and modal analysis to address these challenges.
This can provide insight into the operational condition of the individual components of the crushers. The ability to determine the health of the motor, bearings, gearbox, and rollers as well as the root cause of any impending failures ensures optimum uptime.