TECHNOLOGY •
conveyors and rail wagons – can deliver such immediate and gamechanging benefits ,” he says . “ The merging of these two proven technologies has enabled the most eco-efficient haulage mode now available in mining , by combining the best of each .”
There are operational benefits too , as the rail-running conveyor accommodates tighter curves and steeper angles ; this makes it more flexible in replacing trucks in open pits , while also allowing more efficient routes between shovel and plant .
The rail-running belt conveyor features carriages and rails installed between the head and tail ends of the conveyor system , allowing the belt to be carried on light-wheeled carriages while maintaining the conventional configurations . A host of idler-related maintenance problems are eliminated thanks to this new way of carrying the belt .
“ In addition to the energy efficiency and cost savings of 30 % to 60 % in running the system , there are also CAPEX savings ,” he says . “ Since tensions are usually far lower due to the reduced friction , and much tighter curves are possible , the conveyor alignment and drive locations can be dramatically optimised , reducing expenditure in earthworks , civils , electrical supply and erection .”
FLS invests over half its research and development budget on technology that will have a noticeable impact on reducing emissions , water and energy .
Large rocks in the run-of-mine feed material entering the crushing chamber .
Primary crushing circuit solutions Moving on to FLS ’ s ERC ® in the primary crushing circuit , McKay highlights how improved crushing kinetics allows this technology to boost production capacity – while reducing energy consumption by up to 40 % and extending liner lifespan .
“ With its compact , simple and robust design , the ERC ® has an integrated grizzly that can boost crusher throughput by up to 20 % at the same product size ,” he says . “ The units boast a higher reduction ratio of 1:6 , which compares well to the 1:4 ratio that the industry usually considers as acceptable .”
A cutaway view of the ERC ® crusher showing the screening and crushing chamber process .
He explains how the integrated design ensures that the system avoids the excessive energy resulting from high drop heights between the grizzly and the crusher – a challenge for most other primary crushing configurations . The ERC ® also boasts an adjustment range for close side setting ( CSS ) from 50mm to 300mm ; a fully automatic gap setting system allows for compensation of liner wear and the easy release of tramp metals .
Next generation grinding technology Well-known for its HPGR solutions , FLS has developed the HPGR Pro – the next generation of grinding technology . McKay notes that HPGR technology has already made significant energy-saving
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