Article AT/LEVEL/002-EN

ABB Measurement Products Vale Totten mine | Sudbury Basin | Ontario | Canada

ABB LM80 laser level gauge avoids overloading and jams of ore crusher jaws at new Totten nickel mine Measurement made easy

Introduction Vale, a global mining company headquartered in Brazil and present in more than 30 countries, recently opened a new nickel mine in Canada's Sudbury Basin in Worthington, Ontario. Called the Totten Mine, it's the company's first in this basin in more than 40 years. Developed over seven years, the Totten Mine uses the industry's most modern technology, automation, and environmental practices. Environmental facilities include three water treatment plants, enclosed material handling facilities, and progressive closure planning. When the mine achieves full capacity in 2016, it will produce 2,200 tons per day of copper, nickel, and precious metals for 20 years. In this nickel mining operation, the ore rides on a conveyor to crusher jaws. The jaws must receive an optimal amount of ore at any one time to avoid overloading, jamming, and degraded performance. In choosing an ore level measuring technology to achieve optimum crusher performance, Vale engineers looked for quick response and high accuracy.

According to Jack MacIssac (above), Automation & Production Leader at the mine, ore levels in the crusher jaws can vary from 8 to 15 ft (2.44 to 4.57 m). "We control the speed of the conveyor belt based on crusher ore levels to prevent jams and overload conditions" says MacIssac. "The ore level gauge* must exist in a rugged underground area, characterized by high vibration and a damp ambient atmosphere." *ABB LM80 laser gauge

For more information Further details of the LM80 laser level gauge are available for free download from www.abb.com/level or by scanning this code:

ABB Measurement Products Vale Totten mine | Sudbury Basin | Ontario | Canada

ABB solution Vale engineers selected the ABB LM80 laser gauge to measure ore levels in the crusher jaws. This laser level gauge is a non-contact measuring instrument designed for granular solid materials like ores. Based on pulsed laser technology, it embodies speed and accuracy in a single, easy to use and install product. The characteristically narrow (0.2%) beam divergence of the laser permits accurate aiming towards the target surface without interference from surrounding structures. The gauge's on-board microprocessor calculates distance by multiplying the speed of light by the time it takes for an invisible infrared laser pulse to travel to the targeted ore and back. A second, visible aiming laser helps operators align the measuring laser.

Fig. 1: ABB LM80 laser level gauge is installed on a swing arm above ore crusher jaws

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Fig. 2: Technicians can swing the arm back to the operator platform to perform maintenance on the level gauge.

Fig. 3: A signal from the level gauge controls conveyor speeds to avoid jams and overloading of ore

AT/LEVEL/002-EN | ABB Measurement Products | Vale Totten mine | Sudbury Basin | Ontario | Canada

To install the gauge, Vale engineers mounted it on an arm that could be swung out over the jaw opening. This allows any maintenance of the gauge necessary to be accomplished by simply retracting the swing arm back to the operator platform.

Results

Early in its operation, the LM80 gauge measured the base level for the empty crusher jaws. A comparison of the measurement of ore in the jaws with the base level provides the necessary data to control conveyor speeds.

MacIssac notes that the successful automation of the system avoids manual operator intervention at the crusher. The operator no longer needs be present at the controls.

The LM80 gauge requires no software setup. It sends a 4 to 20 mA signal to a controller that continuously adjusts conveyor speed. It also provides relay outputs for ore level alarms.

The crusher jaws at the Totten mine now operates at optimal efficiency, eliminating jamming and overloading.

Vale has since purchased two additional LM80 laser gauges for similar uses, and is considering a trial for a LM200 model gauge capable of measuring ore level at a 600 foot distance for a different application.

Controller Level LM80 Speed signal Laser pulse Conveyor

Crusher jaws

Fig. 4: The controller regulates conveyor speed based on the ore level signal from the ABB LM80 laser level gauge

ABB Measurement Products | Vale Totten mine | Sudbury Basin | Ontario | Canada | AT/LEVEL/002-EN

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ABB Inc. Level Measurement Products Tel: +1 418-877-8109 +1 800-858-3847 (North America) email [email protected] www.abb.com/level Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

Fig. 5: Totten mine

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts – is forbidden without prior written consent of ABB. Copyright© 2014 ABB All rights reserved

Fig. 6: Totten mine – aerial view

AT/LEVEL/002-EN 09.2014

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