Continuous crusher operation with better level measurement: Application of the month

A creative installation with 80 GHz radar

A large mining operation in Peru runs three crushers and three secondary crushers to process 18,000 tons of material every day. Operators never knew the level in their secondary crusher because dust interfered with non-contact measurement instrumentation, and there was a limited amount of space to mount a sensor. Operators were left guessing  at how much material was entering the crusher, and the process consistently choked up, resulting in regular shutdowns. 

VEGA representatives worked with staff at the mine to create a solution that would end the constant stoppages. They began with the VEGAPULS 69, an 80 GHz radar for the continuous level measurement of bulk solids. The sensor is equipped with special electronics to give it the ability to read through any clouds of dust and dirt. Plus, this radar sensor’s high frequency gives it a narrow focus, which allows it to make measurements in tight spaces – something that came in handy during installation.

Mine technicians installed the sensor above the crusher and inside a small metal box to protect it from any falling material. Despite the tight fit, operators began receiving an accurate and reliable continuous level measurement. Shortly thereafter, mining staff installed VEGAPULS 69 radar sensors on the rest of their crushers.

Running smoothly and safely

Since installing the new sensors, throughput has increased and unplanned shutdowns due to a crusher getting choked up and stopped have been nearly nonexistent. The mine’s safety record has also improved, since unjamming the crusher can be a dangerous job with a lot of opportunities for error. The secondary crushers had been holding back the entire mining operation before they installed the VEGAPULS 69s, and now incoming raw materials are being processed without interruption.