Project Overview
Industry: Mining & Resources
Location: NSW
Duration: 10 Days
Types of Laser Used: 2 x 1000watt Jango
Summary: Precision Laser Cleaning (PLC) was engaged to undertake Pulsed Laser Sweep Ablation (PLA-SA) on the Ball and Semi-Autogenous Grinding (SAG) Mill at a mining operation in New South Wales during a scheduled shutdown.
Due to the short shutdown window and simultaneous sensitive internal works being undertaken within the mill, traditional abrasive blasting and repainting methods were not feasible. The client therefore sought an alternative solution and selected laser cleaning for evaluation, given its ability to deliver controlled, selective coating removal without generating dust or debris that could impact adjacent sensitive work areas operating at the same time.
Given the complexity of introducing new technology into a live mining environment, combined with the high costs and tight timelines associated with shutdown works, PLC conducted an on-site demonstration prior to the shutdown. This allowed the client to validate the effectiveness, safety, and suitability of the laser cleaning methodology before full deployment.
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The Challenges
Highly Restricted Outage Window
The project was required to be completed within a short and tightly controlled outage window. Any surface preparation method that extended mobilisation, setup, or demobilisation time would directly impact the overall outage duration and increase cost.Encapsulation and Scaffolding Constraints
Conventional abrasive blasting and repainting would have required full encapsulation and extensive scaffold installation. This would have been both time-intensive and costly, making it impractical within the available outage window.Dust and Contamination Risk
Abrasive methods generate significant dust and secondary waste, requiring ongoing clean-up and exclusion zones. This would have prevented other works from being undertaken at the same time, particularly sensitive internal works within the mills where airborne dust and contamination were not permissible.Inability to Run Parallel Workstreams
Due to dust, debris, and encapsulation requirements, traditional methods would have forced a sequential approach to works. This would have extended the outage and delayed the return of the mill to service.
The Solution
Laser Cleaning as the Only Viable Method
Laser cleaning was selected as it enabled controlled coating removal without the need for full encapsulation, while generating minimal airborne dust. This allowed partial paint ablation to be performed while sensitive internal mill works were undertaken simultaneously.Purpose-Built Access and Handling
PLC deployed two 1000 W Jango laser systems, designed with integrated lifting points to allow safe craning to elevated work areas. The containerised setup and 50 m fibre cables enabled efficient movement across multiple scaffold levels without repeated relocations.Inline HEPA Extraction
Direct inline HEPA filtration was implemented to capture laser-generated particulates at the point of ablation, ensuring air quality was maintained and preventing contamination of adjacent sensitive work areas.Controlled Work Zones
Localised screening was installed to clearly define the laser work area while still allowing other trades to operate safely in parallel within the mill.Extended and Parallel Operations
Day and night shifts were utilised, with multiple laser systems and dedicated crews working in parallel. This enabled multiple mill areas to be treated concurrently, significantly reducing the overall outage duration.
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The Results
PLC’s laser cleaning methodology enabled coating removal to be undertaken within a short outage window while allowing sensitive internal mill works to continue concurrently. By eliminating the need for full encapsulation, reducing dust generation, and supporting parallel workstreams, laser cleaning proved to be the only practical solution to meet the project’s operational, safety, and scheduling constraints.
This project demonstrates laser cleaning as a highly controlled, low-disruption solution that can significantly reduce outage duration and cost in complex industrial environments.
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