KNOW YOUR WEAR
Wireless sensors providing real, live, actionable data points of an asset’s wear
KNOW YOUR WEAR
Wireless sensors providing real, live, actionable data points of an asset’s wear
Optimised
Optimised Wear Monitoring Solutions
A holistic real-time wear monitoring system for the entire mining and mineral processing chain, delivering unmatched insights for process optimisation and maintenance planning. The OPTIWEAR sensors provide continuous, live data on liner wear, ensuring operations remain uninterrupted. Customers gain peace of mind, expert support, and data-driven insights to optimize production and liner management.
Trucks
Mining dump trucks are used to transport large volumes of mined materials such as ore, coal, and waste rock. The liners inside these trucks protect the truck bed from the abrasive and heavy impact of the materials being hauled. Monitoring this wear is essential to maximise payload, trigger reordering and replacement to ensure efficient, effective and safe operations.
Chute
Chutes direct the flow of crushed ore from one stage to the next, ensuring smooth and efficient material handling. The liners within these chutes protect the chute walls from the harsh impact and abrasive wear of the moving ore, while also playing a crucial role in maintaining optimal flow dynamics. Regular monitoring of liner wear is vital to optimising chute performance, scheduling maintenance, and ensuring the continuous, safe operation of the processing plant.
Primary Crusher
Crushers break down large chunks of ore into smaller, more manageable sizes, a crucial initial step in mineral processing that prepares the material for further refinement. The liners within these crushers protect the crusher chamber from the intense impact and abrasive forces during operation. Regular monitoring of liner wear is vital to optimising crusher performance, scheduling maintenance, and ensuring continuous, safe operations.
Secondary Crusher
Crushers break down large chunks of ore into smaller, more manageable sizes, a crucial initial step in mineral processing that prepares the material for further refinement. The liners within these crushers protect the crusher chamber from the intense impact and abrasive forces during operation. Regular monitoring of liner wear is vital to optimising crusher performance, scheduling maintenance, and ensuring continuous, safe operations.
SAG/AG Mill
Mills crush and grind ore into fine particles, a key step in mineral processing that liberates valuable minerals for extraction. The liners within these mills protect the mill shell from impact and abrasion while enhancing grinding efficiency. Regular monitoring of liner wear is critical to optimising mill performance, planning maintenance, and ensuring continuous, safe operations.
Ball Mill
Mills crush and grind ore into fine particles, a key step in mineral processing that liberates valuable minerals for extraction. The liners within these mills protect the mill shell from impact and abrasion while enhancing grinding efficiency. Regular monitoring of liner wear is critical to optimising mill performance, planning maintenance, and ensuring continuous, safe operations.
Slurry Pump
Slurry pumps are used to efficiently transport (abrasive) mixtures of water and solid particles, such as ore, through mineral processing plants. The abrasive nature of the slurry causes intense wear on the pump’s internal components. Monitoring this wear is essential to maximising the pumps lifespan, minimise downtime, prevent costly equipment failures, and ensure the continuous, safe operation of the processing plant.
Hydrocyclone
Hydrocyclones in the mining industry are critical for classifying, separating, and dewatering materials. The liners within these hydrocyclones protect the interior surfaces from the abrasive slurry, ensuring efficient separation and prolonged equipment life. Monitoring liner wear in hydrocyclones is crucial for maintaining optimal performance, scheduling timely maintenance, and ensuring the continuous, efficient, and safe operation of the processing plant.
Slurry Pipe
Slurry pipes are used to efficiently transport (abrasive) mixtures of water and solid particles, such as ore, through mineral processing plants. The abrasive nature of the slurry causes intense wear on the pipes internal liner. Monitoring this wear is essential to identifying the right time to replace the section, maximising the pipes lifespan, minimise downtime and ensure the continuous, safe operation of the processing plant.
Our OPTIWEAR Sensors
Tailored for Precision: Our OPTIWEAR sensors are fit for purpose, delivering customisable solutions.
The industry’s only non-conductive wear sensor, a game-changer for slurry and wet environments. Designed to deliver precise and reliable data where conductivity often distorts readings, this groundbreaking technology is essential for maintaining data integrity in mills, slurry pumps, and pipes.
Experience unmatched precision with sensors that provide up to 100 measurement intervals and a resolution as fine as 0.2mm. Tailor the solution to fit your specific needs, capturing critical and frequent data points to empower informed insights and decisions.
Configurable sensor arrays allow precise placement of OPTIWEAR sensors, ensuring accurate measurement at critical points. This flexibility ensures that only relevant and targeted data is captured, enhancing the effectiveness of monitoring and analysis. Additionally, sensor placement is not restricted to predefined bolt hole locations, offering greater adaptability to specific operational needs
In most applications, OPTIWEAR sensors can be easily installed into the asset’s liner through a cold-drilled 10mm diameter hole. In mills, these sensors are embedded within the mill liner, with the installation process completed at the foundry.
Our sensor solution offers the flexibility to position OPTIWEAR sensors exactly where needed, rather than being limited to specific locations like bolt holes. This enables precise measurement at targeted points, ensuring the capture of specific and relevant data. Within a mine, critical points on each mill liner—both the lifter and the plate—can be measured simultaneously using an array of sensors, providing a comprehensive view that a single sensor or fixed placement cannot achieve.
Seamless operations are ensured through the integration of our OPTIWEAR sensors, allowing real-time data collection without interrupting or disrupting ongoing processes. This enables continuous monitoring and efficiency without any downtime.
Our Solution
Wear Fusion: Precision data for informed decisions and peace of mind.
Safety is non-negotiable. Our solutions are engineered to uphold the highest safety standards, minimizing risks and safeguarding both people and assets. By integrating our sensors, you create a secure and reliable environment for your operations.
Live reporting of sensor data provides immediate, real-time insights into operational performance. This enables operators to make informed decisions quickly, identify inefficiencies, and respond to issues as they arise, minimising downtime and optimising processes. With continuous access to current data, businesses can maintain greater control and flexibility, improving overall productivity and system reliability.
The ability to set automated alerts ensures continuous monitoring and early detection, offering peace of mind by reducing manual oversight. With this feature, operators can confidently “set it and forget it,” knowing that the system will notify them of critical events or changes, allowing for timely interventions without constant supervision.
The ability to optimize the process is elevated through AI machine learning, offering intelligent insights directly to operators. By integrating real-time data from sensors, equipment, and throughput material, accurate predictions can be effectively communicated and acted upon, such as live charge trajectory or the pebble rate within a mill.
Our approach is centered on partnership, working closely with you to unlock maximum value and deliver tailored solutions that meet your specific needs. Our commitment is to work alongside you, ensuring that our solutions evolve with your needs and continue to provide enduring benefits.
By working with us, you gain access to a team of experts ready to provide tailored advice to drive performance. Our industry experience and data expertise ensure you receive the insights needed to succeed.
Benefits of
OPTIWEAR Sensors
Assets utilised for the extraction, processing and transport of ore are subjected to extreme wear and tear. Wear sensors are a critical technology for modern smart operations. They enable remote real-time monitoring, predictive maintenance, and optimised liner usage, leading to improved operational efficiency, cost savings, and enhanced safety. By providing accurate wear data, these sensors support data-driven decision-making and contribute to the overall success and sustainability of mining operations.
Redefine safety & safety standards
Employees are no longer required to access/enter dangerous areas to inspect or assess the wear life of critical equipment.
Maximise uptime
By having access to real, live, actionable data points of an assets wear, the team can reliably forecast and plan maintenance
Optimise operations & improve productivity
This data combined with feed input and output will empower operators to refine the process where throughput is maximised, maintenance is planned, and costs are minimised. Sensors result in a reduction of labour-intensive manual inspections.
Minimise waste & optimise wear design
The data captured can allow wear liners to be designed to suit the optimal maintenance windows, ensuring maximum wear is achieved. The data will also highlight areas that need to be replaced, their estimated lifetime and identify regions that can remain in service.
Case Studies
There have been over 25 applications to date covering Mills, Crushers, Chutes, Slurry Pumps and Pipes. Over 150 OPTIWEAR sensors installed, without a single failure.
More details to come.
More details to come.
Contact
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Head Office
18 Resolution Drive,
Unanderra NSW 2526,
Australia
PO Box 1246
Unanderra NSW 2526
Australia
1300 BISALLOY (1300 247 255)
1300 BISALLOY (1300 247 255)
About Us
Bisalloy Digital
Bisalloy Digital Solutions is an IoT provider, enabling assets operating in extreme environments to be remotely monitored. We manufacture non-conductive sensors to monitor the wear condition of assets, enabling predictive maintenance and end of life scheduling. We provide industry expertise to optimise operations that maximise return on investment.
Built by experts in mineral processing and abrasion resistant steel.
