IN-PIT CRUSHING & CONVEYING
Installation of large FLS semi-mobile crushing station at S11D Area 5
A slower than anticipated transition to electric truck fleets plus a raft of existing mine expansions and large greenfield proejcts has fuelled a lot of IPCC activity, reports Paul Moore
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In-pit innovation
Iron ore mining major Vale in Brazil last year completed installation of a large semimobile crushing station from FLSmidth at its S11D( Serra Sul) iron ore mining operation, in Area 5 of the mine. The station was added to help open up new mining areas of the deposit.
The first module is 26 m high and includes a 250 t hopper and 205 t grizzly. This feeds the second 14 m high 390 t module which is a powerful 11 m, 2 x 370 kW apron feeder that feeds the third 434 t module – with a large ABON ® sizer with 2 x 800 kW drives capable of 11,500 t / h, in turn feeding the fourth module, a 64 m, 2,400 mm wide 411 t link conveyor which feeds the main pit conveyor. Construction took place in 2024 with commissioning in 2025. The sizer alone weighs more than 270 t, and is an ABON ® 16 / 400CHDTD-RA model.
The modules were constructed in an advanced pre-assembly area for reduction of overlapping work and to provide a greater work area for execution with better visibility of the construction site. Including the structural steel, the overall weight of the station, known as project 20BEBK010, is almost 1,600 t. The pre-assembly of the metal structures was carried out by MIP Engenharia, which contracted Transdata Engenharia e Movimentação for the movement of the modules to their final positions using SPMTs as shown in the attached photo( courtesy Transdata).
Anderson Gomes, Capital Projects General Manager at Vale’ s S11D told IM:“ The installation of the Semi-Mobile Crushing Station( BSM / SMCS) in Area 5 of the S11D mine, located in Canaã dos Carajás, Pará, represents another strategic step in the partnership between Vale and FLSmidth in consolidating the operating model based on In-Pit Crushing and Conveying( IPCC). The project was designed to support the opening of new mining areas by reducing haulage distances, increasing operational flexibility, and reinforcing the efficiency, safety, and sustainability gains that characterise the S11D complex.”
Gomes says that from the engineering phase onward, the project was developed with a strong focus on modularisation, a concept widely adopted in large-scale projects for enabling greater execution predictability and risk reduction during on-site assembly. The station was divided into four main modules – hopper with grizzly, apron feeder, crusher, and sacrificial conveyor – allowing a high level of preassembly, reduced on-site installation interfaces, lower civil works requirements, and an accelerated implementation schedule. This approach also facilitates future relocations of the station in line with the progression of the mining face, a key requirement for large-scale operations such as S11D.
He added:“ Together, Vale and FLSmidth demonstrate how advanced engineering, innovation in comminution, and modular concepts can be applied at an industrial scale to enable more efficient, safe, and sustainable operations. The success of the S11D BSM reinforces the role of semi-mobile crushing stations and large sizers as key elements in the evolution of IPCC systems and establishes another technical benchmark for the global mining industry. The project symbolises the solid, long-term partnership between Vale and FLSmidth, built on collaborative engineering, customised solutions, and a focus on performance throughout the entire asset life cycle. More than equipment supply, technical cooperation between the teams enabled the delivery of an integrated solution aligned with the operational, environmental, and strategic objectives of S11D.”
Why opt for a large sizer instead of a gyratory for this project? Gomes:“ At the core of the solution, a large ABON ® sizer, model 16 / 400CHDTD-RA, was selected following a thorough technical evaluation. The selection considered its suitability for the semi-mobile concept and the specific characteristics of the S11D ore. Compared to conventional gyratory crushers, the ABON ® sizer combines benefits such as low rotational speed, high torque, and specific tooth profiles, which work together to produce the required product size with minimal fines generation and extended wear life of consumables. The low operating speed results in reduced vibration and lower dynamic loads, enabling a simpler infrastructure suitable for underground, surface, fixed, semi-mobile, and fully mobile IPCC installations, as well as retrofit applications.”
He says these characteristics contribute to high mechanical robustness, extended wear component life, and high operational availability. Gomes also pointed out that this technology has been applied for decades across different mining segments, including iron ore, copper, nickel, limestone, and alumina, in operations distributed worldwide. An apron feeder, also included within the project scope, complements the system by providing controlled and continuous feed, designed to withstand high loads and severe impact conditions. Equipped with hydraulic tensioning, centralised lubrication, and lined chutes, Gomes says the system contributes to operational stability and protects downstream equipment, even under demanding operating conditions.
Since commissioning, Vale says the station has demonstrated consistent performance, achieving a nominal capacity of 9,500 t / h, with recorded peak operation of up to 11,500 t / h, and integrating efficiently into the S11D truckless system. Gomes:“ The performance of the BSM directly contributes to mine production stability and reinforces the reliability of the IPCC model adopted by Vale, widely recognised as one of the most advanced in open-pit mining worldwide.”
International Mining | APRIL 2026