IPCC
and fully continuous mining . The sustainable success of this training was proven at Vale ’ s flagship project S11D , where the first fleet of fully mobile crushing units , connected to a network of mining conveyors , now successfully operate .”
He concludes : “ Nowadays , having this unique position being an international mining company fully integrated in a global leader for renewable energies , we are transferring this combined knowledge to our clients in the mining industry . To be green , efficient and highly cost competitive . To determine the feasibility and potential benefits of implementing an IPCC system at an operation , a number of key drivers need to be investigated , understood and interpreted correctly .”
High capacity with high flexibility
FLSmidth ’ s Branco Lalik , Director Mining Systems , says there are a couple of key performance indicators which help to pre-assess the economic feasibility of a fully-fledged IPCC system in a mine and support the early decisionmaking process . “ One of the key questions is ‘ what is the right haulage balance to optimise OPEX ?’ Continuous systems can become viable at truck distances starting at around 2 km . Further the handling capacity is essential to the equation . Generally a minimum mine lifetime of 10 years and an hourly throughput of 2,000- 3,000 t / h should be considered for an IPCC system for primary crushed material to be economically viable . Despite typically being more expensive upfront than truck fleets , the total cost of operation ( TCO ) for IPCC systems is normally favourable . A large reduction in OPEX through significantly less manpower , minimised maintenance and reduced fuel costs , coupled with high availability mean that these systems are a smart investment in the long term , often with a payback period of less than three years . An IPCC system also has a much longer life span than a truck and shovel fleet , requiring fewer capital investments over its lifetime and , as a result , it is more suitable for long-life projects .”
Lalik told IM that FLSmidth currently has two IPCC orders in place that are progressing . Both orders are for semi-mobile crushing stations for hard rock based on primary gyratory crushersone at a large South American copper mine with very high throughput and using the largest FLSmidth gyratory available , the 1600-3300 TSU . The other order is for a large gold mine in the Caribbean region . “ Large crushing stations with a steel supporting structure are an FLSmidth specialty and are only available from a few large OEMs as the general engineering consulting groups are mainly focused on fixed concrete pocket designs . In contrast fully mobile crushing stations on crawlers often require an ideal topography with rather flat and regular shaped mine benches . A true SMC we believe starts at 2,000 t / h or a 20,000 to 30,000 t / d depending on the operational schedule and maintenance plan of the mine and is a specialised modular steel structure housing the crusher . It takes a lot of knowledge and experience to conceptualise and deliver these designs .”
How semi-mobile are SMCs typically expected to be in FLSmidth ' s experience in terms of how often movement is likely or expected ? And is there any standardisation of SMC design across the key OEMs ? “ The frequency of movement not only depends on the mine plan but also on client and local experience with large crusher relocations . There is no industry blueprint for these things . Despite SMCs being modular , each relocation project will always come with issues that need to be resolved and a lot of this comes down to expertise ." Even the transport crawlers that have been developed by OEMs for heavy equipment movement are still more commonly deployed for moving large waste stacking equipment than SMCs , with many SMC moves done by specialist contractors using selfpropelled modular transporters ( SPMTs ). There are other cases where SMCs have been ordered but have never actually been moved due to mine plans changing .
“ The SMC option is still more expensive than fixed due to its design and being steel structure based versus concrete based . But it can be set up quicker with less people on site which can be a major factor for remote mines . I would say typically a mining company investing in the SMC concept will be looking to relocate it a maximum of once a year but more commonly every two or three years , to get the full benefit of its flexibility . I would say that the mimimum relocation time in the industry is about two weeks though obviously it depends on the
FLSmidth says true Semi Mobile Crushing station supply with modular steel structure is a highly specialised market with only a few OEMs having the experience and design capability
distance the SMC is being moved and the gradients involved .”
Aside from relocations , Lalik said the OEM market is highly competitive across only a few suppliers with the design weight and delivery time foremost in discussions in addition to the primary crusher type . We at FLSmidth are focusing on a customised design approach for each customers ' situation whereas others try to offer a more standardised design . But while this may come with a lower initial cost and faster delivery time , it will not take into account unique project aspects such as shallow benches , the amount of steelwork preparation needed around the structure due to the nature of the material or different truck approach cycles
Lalik also emphasised the importance of ancillary aspects on SMCs - particularly with regard to digital aspects - such as hopper radar scanning for oversize and monitoring of liner profiles . These are tangible examples of digital benefits that customers can understand versus overarching ERP type digitalisation . Also new approaches to maintenance are making a big difference in the market , exemplified by FLSmidth ’ s new Mark V Top Service Gyratory Crusher – the TSUV .
Finally , along with areas such as high capacity pressure filtration and dry tails stacking , Lalik sees a firm link between IPCC and FLSmidth ' s MissionZero sustainability program to reduce emissions in mining to zero by 2030 . " Fully electric operations of IPCC systems are beneficial in terms of reduced fossil fuel use particularly when you look at the conveyor which is almost never running empty , versus haul truck
40 International Mining | MAY 2021