In the mining industry, wire ropes serve as the "lifeline" of hoisting and transportation systems, and their safety directly impacts miners' lives and the stability of mine production.
Traditional manual inspection methods suffer from limitations such as low efficiency, strong subjectivity, and susceptibility to missed inspections, becoming a bottleneck restricting safe production and efficient operation in mines.
However, in recent years, many mine managers have adopted the TST wire rope real-time online intelligent flaw detection system, achieving safety monitoring throughout the entire lifecycle of wire ropes and elevating production efficiency and safety management to new heights.
Traditional manual inspection forced mines to make a difficult trade-off between production efficiency and safety verification. The introduction of TST system has completely broken this deadlock: After deploying TST intelligent flaw detection system on its 604-meter-long hoisting wire rope, which operates at a speed of 8 meters per second, this mine not only achieved a smart upgrade in safety monitoring but also a comprehensive list of benefits integrating safety, efficiency, and environmental sustainability.
1. Liberation of Manpower and Time:
Saves the full-time commitment of two professional inspection workers annually. Reduces downtime for rope inspection by over 100 hours—equivalent to gaining more than four extra full-time production days for a single hoisting system. Achieves a fundamental shift from "planned downtime inspection" to "online real-time monitoring," resulting in a qualitative improvement in production continuity.
2. Direct Savings in Energy and Costs:
Reduces dedicated rope inspection energy consumption by over 600,000 kW/h, directly saving over 200,00 USD in electricity costs. Reduces inspection-related energy consumption by over 800,000 kW/h.
3. Safety Technology Supports the country Strategy:
Data from the mine shows that the system helps reduce carbon dioxide emissions by over 800,000 kg/m³ annually. By replacing high-energy-consuming traditional inspection processes with precise monitoring, TST Systems provides the mining industry with "Safe Production" and "Green Production"
4. Data-Driven Value Breakthrough:
Under standardized operation and adequate lubrication, the service life of wire ropes is extended by at least one year. Rope costs are reduced by one-third: annual rope costs significantly decrease from 900,00 USD to below 600,00 USD. This generates direct cost savings of over 300,00 USD per wire rope over its extended service life!
5. Direct Economic Returns:
Annual electricity savings: 20,000+ USD
Annual rope cost reduction: 30,000+ USD
Human resource optimization value: 15,000+ USD (calculated based on the cost of two technicians)
Total annual direct economic benefits: 65,000+USD
6. Investment Return Cycle:
System investment can typically be fully recovered through direct savings within 12-18 months. Net returns several times the initial investment will be generated over the lifespan (typically 8-10 years).
These real data from the production department clearly demonstrate that: safety investment in modern mines can be a high-return value investment; intelligent safety management is the only way to achieve efficient, green, and sustainable mines.
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