9
in SAG and ball mill flowsheets, the impact of duty-only
equipment on grinding circuit performance can be mini-
mized by coordinating the plan maintenance with ore sup-
ply from mining—i.e., feeding the SAG mill with a lower
competent feed during pebble crusher maintenance.
Several solutions are available to increase crushing and
grinding equipment availability through smart mainte-
nance practices and design considerations.
Switching from an in-situ to a bare shaft assembly
maintenance strategy for cyclone feed pumps can save sig-
nificant maintenance downtime. However, a completely
new bare shaft assembly has a higher maintenance cost than
an in-situ one.
Automation is a key enabler in minimizing downtime
during planned maintenance programs. RME’s semi-auto-
mated mill relining system can reduce maintenance time by
20 per cent while improving overall crew safety.
Critical spares of major equipment should be stocked
as part of a proactive maintenance strategy to minimize
extended downtime during unplanned maintenance.
Ultimately, successful mining operations with higher
crushing and grinding circuit availability take a proactive
approach to maintenance, leveraging predictive technology,
smart engineering designs for quick equipment access, and,
when possible, automation to minimize worker hazards.
ACKNOWLEDGMENTS
The authors acknowledge the following personnel and
companies in support of writing this paper:
• Weir Minerals Australia on the discussions regarding
pump designs to improve equipment availability
• Maarten van de Vijfeijken from ABB for providing
examples of online monitoring solutions
• Jon Garnaut from Ausenco’s Asset Optimisation
Team on providing data analysis on duty standby vs.
only cyclone feed pumps
• Pablo Zuniga for cost analysis of bulk handling
equipment
• Peter Litzow, Ausenco’s Technical Manager of
Bulk Handling, for discussions on crushing circuit
availability
• And Ausenco management for the approval and pub-
lication of the paper at the MINEXCHANGE 2025
Conference.
REFERENCES
Bengtsson, M., Svedensten, P., Evertsson, M., (2009).
Improving yield and shape in a crushing plant, Minerals
Engineering, Vol. 22, pp. 618–624.
Chandramohan, R., Foggiatto, B., Lane, G., Meinke, C.,
Ballantyne, G., Reeves, S. and Staples, P., (2023). A
Review of SAG Milling—History of Mill Selection and
Testwork Analysis, in Proceedings of an International
Conference on Autogenous and Semi-Autogenous
Grinding Technology, SAG 2023, Vancouver.
Chandramohan, R., Pyle, M., Lane, G., (2024). In DATA,
we trust—Navigating through the age A.I. in the
Mining Industry. Paper presented at the Future Mining
Conference, AusIMM. Sydney, Australia
Global Mining Review, (2023). https://www.globalmining
review.com/mining/17102023/rme-deploys-worlds
-first-semi-automated-mill-relining-system/
Gwynn-Jone, S., Ogden, T.A., Bohorquez, J., Sims, D.,
Turner, M., Kramer, C., &Smith, S., (2024). Mill
relining automation—applying lessons learned. Paper
presented at Mill Operators Conference. AusIMM.
Perth, Australia
Itavuo, P., (2009). Dynamic modelling of a rock process,
M.Sc. Thesis, Tampere University of Technology,
Finland, pp 1–112.
Lane, G., Staples, P., Dickie, M., &Fleay, J. (2008),
October 22–24). Engineering design of concentrators
in Australia, Asia and Africa—What drives the capi-
tal cost? Paper presented at V International Mineral
Processing Seminar—PROCEMIN 2008. Santiago,
Chile.
Lane, G., &Dickie, M. (2009, April 21–22). What is
required for a low-cost project outcome? Paper pre-
sented at the Project Evaluation Conference, AusIMM.
Melbourne, Victoria.
Major, K., (2003). Types and characteristics of crushing
equipment and circuit flowsheets, Mineral Processing
Plant Design, Practice, and Control—Vol. 2, (eds: A.L.
Mular, D.J. Barratt, D. N. Halbe), SME, pp. 566–583.
in SAG and ball mill flowsheets, the impact of duty-only
equipment on grinding circuit performance can be mini-
mized by coordinating the plan maintenance with ore sup-
ply from mining—i.e., feeding the SAG mill with a lower
competent feed during pebble crusher maintenance.
Several solutions are available to increase crushing and
grinding equipment availability through smart mainte-
nance practices and design considerations.
Switching from an in-situ to a bare shaft assembly
maintenance strategy for cyclone feed pumps can save sig-
nificant maintenance downtime. However, a completely
new bare shaft assembly has a higher maintenance cost than
an in-situ one.
Automation is a key enabler in minimizing downtime
during planned maintenance programs. RME’s semi-auto-
mated mill relining system can reduce maintenance time by
20 per cent while improving overall crew safety.
Critical spares of major equipment should be stocked
as part of a proactive maintenance strategy to minimize
extended downtime during unplanned maintenance.
Ultimately, successful mining operations with higher
crushing and grinding circuit availability take a proactive
approach to maintenance, leveraging predictive technology,
smart engineering designs for quick equipment access, and,
when possible, automation to minimize worker hazards.
ACKNOWLEDGMENTS
The authors acknowledge the following personnel and
companies in support of writing this paper:
• Weir Minerals Australia on the discussions regarding
pump designs to improve equipment availability
• Maarten van de Vijfeijken from ABB for providing
examples of online monitoring solutions
• Jon Garnaut from Ausenco’s Asset Optimisation
Team on providing data analysis on duty standby vs.
only cyclone feed pumps
• Pablo Zuniga for cost analysis of bulk handling
equipment
• Peter Litzow, Ausenco’s Technical Manager of
Bulk Handling, for discussions on crushing circuit
availability
• And Ausenco management for the approval and pub-
lication of the paper at the MINEXCHANGE 2025
Conference.
REFERENCES
Bengtsson, M., Svedensten, P., Evertsson, M., (2009).
Improving yield and shape in a crushing plant, Minerals
Engineering, Vol. 22, pp. 618–624.
Chandramohan, R., Foggiatto, B., Lane, G., Meinke, C.,
Ballantyne, G., Reeves, S. and Staples, P., (2023). A
Review of SAG Milling—History of Mill Selection and
Testwork Analysis, in Proceedings of an International
Conference on Autogenous and Semi-Autogenous
Grinding Technology, SAG 2023, Vancouver.
Chandramohan, R., Pyle, M., Lane, G., (2024). In DATA,
we trust—Navigating through the age A.I. in the
Mining Industry. Paper presented at the Future Mining
Conference, AusIMM. Sydney, Australia
Global Mining Review, (2023). https://www.globalmining
review.com/mining/17102023/rme-deploys-worlds
-first-semi-automated-mill-relining-system/
Gwynn-Jone, S., Ogden, T.A., Bohorquez, J., Sims, D.,
Turner, M., Kramer, C., &Smith, S., (2024). Mill
relining automation—applying lessons learned. Paper
presented at Mill Operators Conference. AusIMM.
Perth, Australia
Itavuo, P., (2009). Dynamic modelling of a rock process,
M.Sc. Thesis, Tampere University of Technology,
Finland, pp 1–112.
Lane, G., Staples, P., Dickie, M., &Fleay, J. (2008),
October 22–24). Engineering design of concentrators
in Australia, Asia and Africa—What drives the capi-
tal cost? Paper presented at V International Mineral
Processing Seminar—PROCEMIN 2008. Santiago,
Chile.
Lane, G., &Dickie, M. (2009, April 21–22). What is
required for a low-cost project outcome? Paper pre-
sented at the Project Evaluation Conference, AusIMM.
Melbourne, Victoria.
Major, K., (2003). Types and characteristics of crushing
equipment and circuit flowsheets, Mineral Processing
Plant Design, Practice, and Control—Vol. 2, (eds: A.L.
Mular, D.J. Barratt, D. N. Halbe), SME, pp. 566–583.