Extended maintenance or unexpected repairs can cause increased downtime, costs and aggravation. All machinery needs maintenance, even heavy-duty equipment like crusher rolls. Returning them to the manufacturer is a costly and time consuming process. But this was exactly what happened. Until we came into the picture. We provided for a way to offer a safe, clean and cost effective way that could be integrated in the existing product facility. The aim was for 100% tension-free heating to avoid any damage or structural anomalies. The results of our hard work can be found in the ET500, a customized heater that can heat a 100 ton grinding roll.
To avoid tension we wanted to achieve a heating process with a maximum of 1°C per 5 minutes. Using a Siemens touchpad with custom software, the heater offers the user a guaranteed tension-free and controlled process. Designed specifically for the mining industry, it is able to heat up parts with an outer diameter, ranging from 500 mm up to 2000 mm. The height of the part can range from 1000 mm up to 2000 mm. For a 100 ton roller, it turned out be the most efficient if the heater moved and the roller stayed stationary. Using a relatively light and easy to handle induction coil, the equipment footprint is minimal and the cost effectiveness maximal.