Automated robot removes metal crust
BHP Billiton is using a remotely-run robot for the extreme task of controlling the crust on molten metal in its Kalgoorlie Nickel Smelter.
The smelter in Western Australia produces granulated nickel matte from dry nickel-in concentrate. During the process, pots of molten metal are moved to tilting stations and poured through jets of water.
The moving procedure cools the metal, causing a crust to form across its surface. The crust can then break away, interrupting the metal flow and leading to a steam explosion.
Previously, staff used long paddles to manipulate the crust during pouring. This task required layers of protective clothing in an extreme environment.
Using automotive technology, the Kalgoorlie facility now operates crust-controlling robots from a remote position to lessen the risks to staff.
The project was started in the latter half of 2006, with the initial aim being to just replace the long paddles with a manually-operated robotic system. This required the operator to be operated from nearby, necessitating the use of protective clothing.
During the on-site installation and commissioning process, the development team decided to apply full automation, allowing control of the crust from a remote, climate-controlled area.
According to the company, the granulation cycle time was decreased by 12%, resulting in increased productivity.
25-Jun-2008
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