Intelligent Lining Technology Minimises Risks in Mining

In mining, materials handling is very challenging for engineering and equipment alike. Wherever bulk materials are transported, stored, or processed, damage and wear cause unplanned downtime and inefficient processes. Losses can now be avoided based on intelligent lining technology. The technology involves a plastic sheet equipped with sensors that monitor the condition of the sheet. Suppliers are the plastics processor, Röchling Industrial and the supplier of semi-finished thermoplastic materials, Maizey Plastics. 

Lining material made of plastic has been used in mining and materials handling for years. There, the lining material protects underlying components and machines and, owing to its good sliding properties, ensures the smooth flow of bulk materials. Sensors that monitor processes in mines or in plants are also not new.

The plastics processor Röchling Industrial has now combined these technologies, Smart Matrox^® is the name of the new intelligent plastic sheet equipped with sensors. It not only combines the properties of the lining materials previously used, but it also provides information about the wear and temperature of the material.

Intelligent lining technology prevents damage due to fires in mines 

The use of wear sensors and temperature sensors has proven particularly useful in mining and has already prevented major damage due to fires. “We have successfully tested both sensor types in our Matrox^® material and are already providing reliable data for customers with applications in mining and coal-fired power plants.

Tested areas of application are chutes and debris beds on conveyor lines, where a sliding sheet under the conveyor belt made from Smart Matrox^® monitors the temperature of the conveyor system. In use, the material has already prevented major damage from overheating and fire,” explains Michal Sladek, Industry Manager Mining Röchling Industrial. Smart Matrox^® is also suitable for numerous other areas, and the number and placement of the sensors can also be individually adjusted.

Temperature sensors and wear sensors assume important warning functions 

Topics such as pro-active and predictive maintenance and automated spare parts supply can also be implemented much more easily based on intelligent lining technology. “Our experience of Smart Matrox^®, especially in remote locations where material monitoring is complex, has been excellent. The material provides an important warning function and enables easy monitoring even remotely,” says Sladek. The sensors in the sheet emit a signal when predetermined limit values are reached. The replacement of components can then be scheduled in time.

The sensors are integrated into the sheet during the manufacturing process. While wear sensors and temperature sensors have already proven themselves in mining, other types of sensors can also be integrated into the sheet at the customer’s request to measure different parameters such as water flow, loading pressure or noise level. All measured data are collected by a so-called SmartBox and made available to users on a platform. A dashboard or mobile devices can be used to retrieve and represent any desired data.

Smart Products at Röchling Industrial

At Röchling Industrial, Smart Products are components equipped with integrated sensors to permanently monitor important process data of a component. Smart Products such as the Smart Matrox^® mentioned above form the basis for an early warning system that draws attention to critical factors – before failures occur. In this way, automatic ordering processes can be initiated and/or components can be replaced before they fail. Smart Products from Röchling are designed as plug & play and are delivered ready-to-install.

Smart Plastics at Röchling Industrial

Röchling Industrial also supplies identifiable and authenticate able plastics. These Smart Plastics contain tiny marker particles that provide every component with an unmistakable identifier. In this way, it can be unequivocally determined whether a product is an original component. Customers gain greater process reliability in the operation of systems; unlawful complaints can be avoided and the SmartMarker particles provide reliable counterfeit protection. The markers are invisible and do not affect the technical properties of the material.

Smart Plastics with marker particles can be integrated into various Röchling Industrial products. It is also available for the Matrox^® lining material if desired.