IPCC
incorporate Metso ’ s sensor-based ore sorting solutions .
Enhancing efficiency – TAKRAF ’ s IPCC systems & sustainable mining
TAKRAF Group has announced the award of two IPCC contracts in recent months . It says this once again demonstrates the importance of continuous material handling as one of the key technologies for cost-effective and sustainable operations , parallel to a phase of evolution of truck haulage towards greener and cleaner battery or hybrid-powered vehicles .
The commonly used term of IPCC does not entirely correspond to the actual layout of the system , as semi-mobile or stationary crushing plants are usually installed outside the pit rim , or at least on the edge , with the truck dump level on the topographical surface . However , IPCC is the buzzword and TAKRAF ' s new projects in Africa include crushing plants close to the pit together with an integrated conveyor system , as well as other processing equipment and facilities .
The contract between TAKRAF and Rio Tinto includes the design , fabrication and delivery oft wo primary crushing plants incorporating two TAKRAF X-TREME class sizers ; one secondary crushing plant incorporating four TAKRAF sizers ; two rail mounted stackers ; two rail mounted reclaimers ; and two wagon loading stations with buffer silos . Then it includes a complex conveyor system with transfer stations for the above equipment , including a technically sophisticated long downhill conveyor between the secondary crushing plant and the stockyard ; as well as electrical and control equipment and stockyard auxiliaries .
In order to achieve the desired annual production rate , the crushing system has been sized with a design capacity of up to 13,200 t / h . Interestingly , all stockyard and wagon loading equipment is also designed to allow for future capacity expansions . Additional contracts are planned for construction and commissioning support , long-term maintenance and spare parts supply .
TAKRAF then received a second IPCC system order for iron ore for SNIM ’ s F ’ Derick operation in Mauritania . The system consists of a primary crushing plant with a gyratory crusher fed by 200 ton mining trucks , a secondary crushing plant with pre-screening , an additional transfer tower ( to implement an exit to a stockyard at a later stage ), a train loading station with a capacity of 100 80-100 ton wagons per hour , and a conveyor system between the aforementioned system components .
The F ’ Derick deposit , with its high purity haematite ore , plays an important role in Mauritania ' s iron ore production . The new system will contribute to increasing current production from 12 Mt / y to 18 Mt / y .
Overall layout of the TAKRAF integrated IPCC and material handling system for the Simandou iron ore complex in Guinea
For both projects , TAKRAF says it is able to leverage its long-standing experience and expertise from previous large material handling projects in Africa and elsewhere - these include the CBG bauxite expansion project in Guinea and the Guelb 2 iron ore tailings handling project in Mauritania . It told IM : “ The overall aim is to safely achieve high technical availability and a long service life with the possibility of system expansions through state-of-the-art engineering solutions and effective maintenance strategies . This contributes to the local ( and global ) requirement for effective use of all resources as part of a sustainability strategy with minimal impact on the surrounding environment .”
MMD – expanding in-pit processing solutions
Over the past year , MMD says it has witnessed an increased demand for its Semi-Mobile Sizing Stations . These modular stations offer a versatile solution , combining the efficiency of fixed installations with the flexibility of mobile units , catering to the evolving ESG needs of modern mining operations . “ Their ability to adapt to varying site conditions , optimise material handling , and minimise infrastructure costs has garnered substantial interest from mining companies worldwide . In recent years , a wide range of Sizer Stations and systems both large and small have been installed in many IPCC projects around the globe including Canada , Thailand , Laos , UK , France , and seventeen sizing stations to a single operation in China to name just a few .”
One of the recent notable projects is for the Winning Consortium Simandou ( WCS ), who secured a mining concession for Simandou Iron Ore Blocks 1 & 2 in Guinea , led by Winning International Group . This area hosts the world ’ s largest untapped open-pit iron ore deposits with highgrade iron content . WCS invested in MMD equipment for efficient mining , including Mineral Sizers and Apron Feeders tailored to the project ’ s needs . Each Semi-Mobile Sizing Station features MMD ’ s 1150 Series Sizers and D10 Apron Plate Feeders , capable of handling 4,500 t / h run of mine iron ore . The purchase also includes technical services and spare parts for maintenance . Beijing MMD expressed pride in providing equipment for Guinea , highlighting its significance . MMD adds : “ Winning Consortium Simandou ' s decision underscores their commitment to sustainable and advanced resource extraction . This investment reinforces their pivotal role in the Simandou project ’ s development .”
MMD ’ s latest innovation , the iFMSL , combines the advantages of the FMSL ( Fully Mobile Surge Loader ) with Bulk Sorting Technology presenting an opportunity to enhance mining operations ' efficiency and cost-effectiveness . “ By seamlessly integrating this technology into the live dispatch system , mining companies gain real-time insights into each truck ' s ore grade and monetary value as it ’ s being loaded . Thus creating a more much efficient haulage system as it automatically takes it to the appropriate destination . This integration empowers operators with greater control over the system , facilitating improved fleet management and enhancing ore body control with enhanced granularity .”
The MMD Apron Plate Feeder meters on pull out , ensuring a consistent bed and flow rate control , ideal for sensing and maximising the detection of valuable materials . The ore analyser is placed in a safe location away from potential impacts . It maintains a consistent and optimal distance to the material being processed , regardless of lump size , making sure it ’ s safe , consistent and reliable .
By combining its innovative Fully Mobile Surge Loader and Bulk Ore Sorting solutions , MMD has created the iFMSL
36 International Mining | MAY 2024