CONVEYING
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FLSmidth ’ s High-Performance Conveyor Group told IM that its Rail- Running Belt Conveyor product line is continuing to gain momentum . In the ‘ RRC ’ system , rail carriages that each weigh about 300 kg carry the belt in an almost frictionless run between tail and head , eliminating most of the losses and maintenance issues of conventional idler rolls .
The first mining-scale RRC reference is on track for bringing 5,000 t / h of copper ore from an in-pit crusher by October 2025 . Layout for this RRC conveyor has evolved with the mine plan , requiring an extension to a 3.5 km length that includes two horizontal curves with radii of about 1,500 m . The curves both eliminate a transfer point and serve as a test bed for the owner ’ s future long overland conveyor haulages , such as one being studied to carry ore at 8,000 t / h over tens of kilometres . FLS ’ s commercialisation of the RRC technology is in partnership with a technology-leading global mining company and the University of Newcastle , Australia , from whom FLS holds exclusive licenses . The same FLS customer has progressed a second RRC system designed for 13,000 t / h into fabrication and construction .
During the the last few months , a few FLS customers have identified RRC as a lead haulage technology for significant projects at the FS2 and FS3 stages . These selections came after paid FLS studies comparing the CAPEX and OPEX of conventional and RRC systems . The studies were able to quantify the benefits of the RRC system ’ s unmatched haulage efficiency , maintainability , and adaptability to challenging terrain . In one case , the RRC ’ s ability to ascend at steep angles ( 22 degrees for this application ) offers comprehensive advantages over the multiple flights needed to zig-zag conventional conveyors up to the plant .
Overland Conveyor Company , itself also part of the FLS High- Performance Conveyor Group , has recently released Belt Analyst 24 , the
FLSmidth ’ s High-Performance Conveyor Group told IM that its Rail- Running Belt Conveyor product line is continuing to gain momentum
latest iteration of OCC ’ s suite of conveyor design and analysis software tools .
The release focuses on enabling conveyor engineers and operators to accurately use the latest trends in conveyor design , while also easily communicating and documenting calculation results . This includes Belt Analyst ’ s “ Data Driven Analyst ” module which allows users to directly import data from operating conveyor systems to ensure the calculation model represents an accurate digital twin of the real conveyor system . Belt Analyst ’ s horizontal curve analysis module has also been updated to more easily document the effect of variable operating conditions on curve performance . Additionally , the software is continually modernised to utilise the latest programming languages to ensure calculation efficiency and compatibility the latest computer hardware . braking to recover energy and feed it back into the power grid , enhancing energy efficiency .
Pietila says that independent analysis of Railveyor ’ s energy consumption shows that it achieves fuel-related emissions that are orders of magnitude lower in the long term than many traditional technologies . This has been observed and documented at an installation in Canada , which realised carbon emission reductions up to 39 % when compared with the truck fleet previously utilised at the mine .
The system is fully autonomous , allowing for single operator control – regardless of scale . This contrasts significantly with truck fleets , which require more operators and supervisors as they expand . Railveyor also enhances site health and safety by reducing dust and noise levels , as well as the system operating on its own dedicated and predictable route path .
Applicable in both underground and surface environments , Pietila says that Railveyor has delivered proven value to mining customers in a range of applications for over 15 years . Among these is a South American customer in a surface application , who wanted a lower maintenance operation with less downtime compared to traditional conveyors , while also taking advantage of Railveyor ’ s flexibility that would allow for an overall reduced footprint for their haulage system . Similarly , at an underground operation at Agnico Eagle Mines ’ Goldex complex in Quebec , Railveyor lowered operating expenditure by up to 75 % and reduced carbon emissions by 39 % The flexibility of the Railveyor application allowed the mine to get closer to the ore body , increasing the life of mine .
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Moving on to conveyor best practice and maintenance , President Emeritus at Martin Engineering , R . Todd Swinderman , recently published a valuable in-depth article on this topic . He states : “ Conveyor systems are the veins and arteries of mining and processing . Mined material is extracted with differing sizes , weights and traits which react in their own unique ways to being conveyed . Some spread , some collect on one side , some stick and some emit excessive dust . These different qualities can require slight changes in conveyor design .” He adds : “ Modern systems are being tasked with moving greater volumes of cargo - at higher speeds - than ever
before . Yet , the common practices in conveyor specification and design are out of date compared to the current safety requirements , serviceability innovations and greater control over fugitive material .”
He argues that many mine operators view conveyors as simple equipment that merely transports material from Point A to Point B at a prescribed rate . “ In reality , they are complex systems that interact with virtually all major processes , and shortcuts taken in the design and specification stages will have dramatic and farreaching effects on safety , productivity and the
Strategically-located access doors facilitate inspection and service
54 International Mining | FEBRUARY 2025