Bauma plant optimization_solutions
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Every aggregates plant is unique. We will show you some rock hard examples on identifying bottlenecks and resolving inefficiencies to maximize production rate and reduce production costs. See more and contact us on metso.com
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Bauma plant optimization_solutions
- 1. © Metso© Metso Metso strategy 2014-20171 Plant Optimization Solutions Improve the profit of your existing plant
- 2. © Metso© Metso2 Today’s business environment Less new plants but increased capacity or efficiency for existing plants Evolving requirements of end products to serve the aggregate market Less labor on site and higher grade of automation
- 3. © Metso© Metso3 You have an existing plant You’re looking to increase profit Metso’s long experience in plant refurbishment can help optimize your plant Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Rising costs but stable income Why optimize your operation ?
- 4. © Metso© Metso Bauma 2016 - Aggregates Academy – Plant Optimization Solutions4 Main objectives in optimizing your plant Safety is n° 1 Savings in consumption water, energy, trucking, wears and spares Adapting end products to market requirements Production capacity aligned with designed production output, less downtime Easy Operation less personnel more automation
- 5. © Metso© Metso Phase 1 Analyse your process and identify bottlenecks Phase 2 Propose technical and business solutions Phase 3 Project implementation 3 phases in plant optimization Improve your existing plant operation with process design and expertise to minimize CAPEX 5
- 6. © Metso© Metso Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Experience in plant optimization 6 From our long experience in the aggregate business we’ve defined 6 main categories for plant optimization
- 7. © Metso© Metso 6 plant optimization categories Refurbishment types Bauma 2016 - Aggregates Academy – Plant Optimization Solutions 6) Replace almost all sections 7 2) Plant section replacement 4) Plant extensions 3) Create a process break 5) Relocate a section 1) Machine replacement
- 8. © Metso© Metso Plant optimization categories / objectives Production Capacity Better end products Reduced consumption Easy Operation 1) Machine replacement 2) Plant section replacement 3) Create a process break 4) Plant extensions 5) Relocate section 6) Replace almost all sections 8 Bauma 2016 - Aggregates Academy – Plant Optimization Solutions
- 9. © Metso© Metso Plant optimization cat. 1 Machine replacement 9 • Full availability • (<5% downtime for maintenance) • Easier and safer maintenance • Less water consumption Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Capacity Products Reduced Consump. Easy Op • Poor availability • (>25% downtime)
- 10. © Metso© Metso Plant optimization cat. 2 Plant section replacement 10 Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Capacity Products Reduced Consump. Easy Op • One energy efficient HP3 • Safer maintenance environment • Automation upgrade • Better end product • Replacing two 20 year-old crushers
- 11. © Metso© Metso11 Plant optimization cat. 3 Create a process break Capacity Products Reduced Consump. Easy Op Bauma 2016 - Aggregates Academy – Plant Optimization Solutions • Secondary stage operates steadily • Stockpile offsets variations from primary • Feed control to secondary crusher is now possible.
- 12. © Metso© Metso Plant optimization cat. 4 Plant extensions 12 Capacity Products Reduced Consump. Easy Op Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Furnished by client Metso supply • Incorporate existing machines • Metso’s CE certification for new and existing sections
- 13. © Metso© Metso Plant optimization cat. 5 Relocate section 13 Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Capacity Products Reduced Consump. Easy Op • Relocating closer to quarry face • 25% savings on truck haulage cost • 30% in noise emission
- 14. © Metso© Metso Plant optimization cat. 6 Replacing almost all sections 14 Bauma 2016 - Aggregates Academy – Plant Optimization Solutions Capacity Products Reduced Consump. Easy Op • Replacing almost all sections with little downtime • End product adapted to new market requirements • Increased plant efficiency and lifetime
- 15. © Metso© Metso15 Based on Metso’s long experience in plant refurbishment and design, we are confident our 6 categories illustrate how we can help you meet your objectives. Plant optimization solutions Each solution is unique and is adapted to fit your operation and your budget Production Capacity Better end products Reduced consumption Easy Operation 1) Machine replacement 2) Plant section replacement 3) Create a process break 4) Plant extensions 5) Relocate section 6) Replace almost all sections
- 16. © Metso© Metso16 Resources: • Process optimization • Plant engineering • Design of supports and chutes • Automation engineers • Site implementation • CE certification abilities Backed with proven Metso equipment & Services: • Jaw, cone and impact crushers • Feeders, screens and scalpers • Conveyors • Life Cycle Services for Aggregates Rely on Metso’s team of process experts and design engineers For complete plant optimization services
- 17. © Metso© Metso Knowledge, People, Solutions Hundreds of plants designed by Metso operating worldwide Date Author Title17
Editor's Notes
- Hi I’m FB I’ll be presenting Metso’s experience in Plant Optimization solutions to improve the profit of your existing plant. My presentation will take about 15 min. If you have questions don’t hesitate to ask after each slide and of course we will have time after the presentation to any questions you may have.
- We see less new plant projects in today’s environment in the aggregates business. On the other hand, there is often the need to increase the capacity of existing plants. New standards for products have appeared too and older plants need to be modified to produce them Personnel on plants is also an issue and many plants do not have or have insufficient automation to run smoothly without human intervention. That is the background.
- Your plant exists, has a deposit, access, serves a market It becomes increasingly difficult to keep costs at bay while selling prices are stable Profitability has to be anticipated Metso ‘s experience is significant and we base this analysis on dozens of cases.
- Increase nominal capacity or simply being able to produce along the shift close to the nominal capacity End products have evolved in terms of shape and size with new standards for asphalt or ready-mix Energy, trucks or water are costs on which all savings will be welcome. Reliable operation secured with performing automation and costing less personnel And of course let’s not forget the safety and the environmental aspects which are an important element in today’s operations.
- Phase 1 Analyse your process, identify the bottlenecks in the process and address those issues in Phase 2. In Phase 2 we’ll discuss our technical solutions with you and define the right business solution for your operation. In Phase 3 Metso has the capabilities to carry out the full project management, from design to commissioning. Metso has engineering teams, design teams to carry out projects no matter what size.
- We have a long history in plant refurbishment. Hundreds of revamping projects over the years, 40 plant refurbishments /p.a. in France alone. Whether you need to replace a machine and its structure or a complete section we put ourselves in your shoes and are concerned with your operational needs and challenges (new crusher feed, new automation, etc.. ). That is how we selected some categories we are going to analyze now
- Machine replacements are safe and easy replacements of one or two machines. Plant section replacement means adding also hopper, feeder, conveyor, to the previous crushing or screening machine Process break as we will see is a smart way to increase efficiency without new machines Plant extensions are new sections created mainly to produce new products Relocation is possible even with stationary plants and allows to cut haulage costs when quarry face has moved along years And finally…almost new plant on an existing site
- Based on the 4 main objectives to optimize and our 6 main categories of plant refurbishments, we have filled a « hit » table, that we are going to detail for each example. Of course, the « marks » are given for the specific examples and might vary with different cases.
- Getting more from your machine with an upgrade However please keep in mind that a machine replacement often requires upgrading the machine environment we’re talking about chutes and structure. If you talk about screens often being a bottleneck – give a positive… « that’s why Metso’s new range of screens are incorporate easier and safer maintenance and more ergonomic for the operator ». New washing screening station Upgraded capacity End products quality upgraded Maintenance friendly screen New process with less water consumption « green design » New galvanized ES screen for rust resistance (show the trolley) By the way we invite you to attend the ES screen platform on the stand and find out more about the Metso range You may only need to replace a worn machine to be more effective. Metso can do this quickly and efficiently
- Make more focus on energy efficiency, feed controls on crushers (through automation control loops, intergrated control … ) Secured place of operation with good access platforms, safety rails, etc… ! Old crushers fed directly from hopper, without regulation New crusher fed with a vibration feeder, with regulation Savings in power consumption using new generation of cone crushers. Control of the crusher feed with the feeder.
- Replaced machines in the primary and inserted a stockpile between primary and secondary stages. Limited space on site to insert stockpiling conveyors & reclaiming tunnel. Explain benefits of having a buffer stockpile to keep steady production and allow feed control. Fit machines into the existing primary for more savings for customer to keep existing concrete stations and fit Metso machines into the primary. Limited time , really tight deadline to do the machine replacement and get the operation back into production (less than 4 months)
- For utilizing exisiting equipment, compared to a new plant, your advantage is 35% savings on cost. Metso will endorse of course the new components and moreover endorse the existing ones, conduct plant risk analysis and deliver a full CE certification for the complete plant.
- The client’s layout evolved, he was spending a lot in trucking costs. With Metso’s process expertise the solutions proved to move the existing primary station closer to the quarry face We relocated same steel structure , with new C jaw crusher and new vibrating feeder with existing feed hopper and existing grizzly and combining new and existing conveyors With the effect of 25% savings on truck haulage costs And a 30% decrease of noise emission We also want you to know that you can move stationary plants, this is the proof that it’s possible and we have several other references.
- Talk about the time it took to get the operation running, working within the existing layout. On this picture you can see a total plant refurbishement, but a big one. A brownfield project which becomes a greenfield project by using parts of the existing equipment Secondary produced ballast was no longer performing: new section Reserve deposit was located below the previous primary: new section Tertiary section was OK and kept In the middle of the plant you can see the new equipment. Three new buildings, new conveyors, new stock pile. We have increased the production capacity, efficiency, availability and did the job while the previous plant was running every day, then we connected in a few days the new one.
- We have realized hundreds of new plants and plant upgrades all over the world. It will be a pleasure for us to work with you on future projects. Thank you very much for your attention. In 2015 and previous years – 40 projects per year on refurbishment of the kind you saw in this presentation