Mining operations require strong and reliable equipment. This is to guarantee the precise and safe extraction of metals and minerals.Air compressors are among the essential pieces of machinery in this sector. They are now used in every step of the mining process.

However, compressed air systems frequently encounter problems like leaks. These raise energy expenses and reduce equipment performance, compromising overall safety and productivity.

An acoustic mining camera has emerged as a useful and efficient tool for locating compressed air leaks. Even in complicated and noisy surroundings, these cameras can rapidly and precisely identify the leak’s source with little operator training.

Consequently, miners can promptly implement remedial measures to minimize energy waste, minimize safety hazards, and enhance equipment performance. Continue reading to learn more.

What is the use of compressed air in mining operations?

First, we need to understand how compressed air helps mining operations to understand the role of acoustic imaging. Air compressors are widely used in the mining sector to power machinery, deliver clean air, and provide ventilation. This is to promote safer and more effective processes. Compressed air serves several tasks, such as:

The drilling process

Compressed air powers a rotary drill bit. This allows it to penetrate solid ground and reach its minerals.

Air circulation systems

Having enough safe, breathing air is essential for miners who work underground. Compressed air provides underground ventilation. Compressors also provide safe, clean air to refuge bays in an emergency, allowing miners to seek breathable cover.

Blast-controlled explosives

These are employed to break rocks and other hard materials in the mining sector. Compressed air helps safely explode explosives by producing high-velocity streams.

Tools and equipment

Clean, dry air is necessary for the optimal operation of pneumatic tools used in mining activities. Air compressors supply this air to mining equipment, enabling it to function without electricity. Compressors can power drills, hacksaws, and wrenches for reliable and secure underground mining.

Handling materials

Certain materials, like coal dust, are easier to handle when fluidized with compressed air. Additionally, it can transport mining materials for easy mobility.

Extraction of methane gas

Methane gas accumulation in a mine can be fatal and raises the possibility of respiratory issues and static sparks. Safely designed air compressors can use blowers and vacuum pumps to help extract methane gas.

Tidying up

Compressed air can effectively clean filters to remove unwanted particles. It is also a clean air supply that can preserve materials and equipment against dirt and debris. This can prolong everything’s optimal condition, increase efficiency, and decrease downtime.

Sprinkler systems

The sprayers, which are pipes at the bottom of the tanks, are used to introduce compressed air into the tanks. The pipes’ tiny holes allow the bubbles to be dispersed uniformly around the tank.

Refining and smelting

This is the process of heating and extracting the most useful metals from raw materials. Compressed air is also used in the refining process to oxidize undesirable components and minimize material waste.

Why does compressed air leak detection matter?

Leaks are common in compressed air systems. They frequently happen at joints and weak spots, which results in pressure changes. Leaks can raise energy expenses by requiring more effort from the compressor.

Pneumatic tools may become less effective as a result, and the task may take longer to do. Also, leaks lengthen compressor run times and cause needless compressor cycling. This reduces equipment longevity and raises maintenance expenses.

The expenses associated with compressed air leaks in mining operations

Leaks usually lose 25–30% of the air in compressed air systems. That implies

• More energy expenses.
• The price of purchasing more compressor equipment to fulfill the needs for compressed air tooling.
• 30% shorter compressor life translates into 30% more expensive replacements.
• The extra expense of maintaining extra equipment.

Using acoustic imaging to find compressed air leaks

Mining businesses can use condition monitoring technology to address the mining industry’s issues. The acoustic imaging camera is a potent tool for mining condition monitoring. It is made especially to find partial discharges like arcing and corona in medium and high voltage electrical systems, as well as compressed air leaks.

The camera is perfect for the tough environment of mining operations. It is equipped with microphones that allow it to detect and locate even very quiet noises at large distances. Its sensitive microphones are also useful for high-voltage system inspections. These require keeping a safe distance from electrically charged equipment.

Using proprietary algorithms, the acoustic imager first detects a sound source at a possible leak location. Then,it interprets the sound as a leak. A color map that is placed over the visible light image reveals the precise location of the leak. The screen shows either a live video or a still image of the results.

Rapid scanning of large areas makes it possible to find leaks considerably more quickly than with previous techniques. Additionally, it permits filtering based on frequency and intensity ranges.

Benefits of an acoustic imaging camera for mining operations

• Compared to conventional procedures, it enables specialists to do their examinations ten times faster.
• The non-contact camera has a 0.3 m to 130 m (1 ft) operating distance. It allows for condition-based maintenance over wide regions in a safe, effective, and continuous manner.
• Early detection of compressed air leaks minimizes energy waste and financial losses.
• It helps identify partial discharges in medium and high-voltage electrical transmission equipment early on. This prevents potentially hazardous mishaps.
• It keeps unscheduled downtime from high voltage (HV) electrical component failures at bay.
• It enhances thermography equipment for a more thorough examination of mining equipment assets.
• It facilitates uninterrupted power supply and improved operational continuity.
• Incorporating it into mining facilities’ maintenance cycle is simple and requires little training.

The sum up

Leaks in the compressed air system can negatively impact mining operations. This raises maintenance needs, lowers tool efficiency, and increases energy expenses. Utilizing condition monitoring technologies for air compressors can help mining firms operate as efficiently and safely as possible.An acoustic mining camera is an effective way to keep an eye on the state of mining facilities, find compressed air leaks early, and enhance operational continuity.