IPCC
MCI believes compact bucketwheels combined with conveyors still have an important place in mining
all in one machine.” And MCI is not only focused on large bulk mines.“ We are also looking to deploy compact versions of our Leopold GEN3 BWE in smaller mines and quarries, with a capacity of about 500 loose cubic metres per hour. We already have two such projects, the first with a BWE removing sand and clay overburden for a quarry and another project at a typical quarry mining application.” MCI does have experience with larger BWEs at the other end of the scale, in their more typical application – including two BWEs originally supplied by thyssenkrupp in Thailand handling up to 6,000 loose cubic metres of overburden. These machines are now being serviced and supported by MCI. Mentges:“ So in between this range, we see a real gap in the market for compact BWEs.”
He added that the combination of BWEbased, used in pre-stripping, IPCC with trucks is also an interesting option.“ What we are now also doing within MCI is providing mine planning services including detailed IPCC trade off studies. Now with hybrid and electric truck potential combinations with IPCC it is getting much more interesting in that you can combine a truck shuttle with IPCC, and assuming the power is renewable for the truck battery charging, you are still achieving zero emissions but with the flexibility of trucks combined with the IPCC efficiency and productivity.”
In-pit bulk sorting for high tonnages
An increasingly important aspect of in-pit crushing and conveying is the introduction of in-pit bulk ore sorting – as by separating ore from waste at an early stage, and maintaining ore heterogeneity earlier in the process, bulk ore sorting eliminates the need for processing large volumes of low-grade material. This results in higher processing efficiency, reduced energy consumption, and increased overall productivity.
A leading proponent and supplier of bulk ore sorting solutions is MMD, whose Group Business Development Director Chris Pearson told IM:“ The targeted processing enabled by bulk ore sorting significantly lowers operating costs by hauling ore and not waste materials. Minimising the amount of material that needs further processing not only reduces energy consumption but also leads to lower transportation and handling costs.” He adds:“ Bulk ore sorting provides the ability to control and make informed decisions in the mining process. It enhances the ore grade control by sorting large volumes of ore based on their mineral content. This technology can greatly improve the efficiency and effectiveness of mining operations by eliminating waste early in the process and focusing energy and resources on processing the most valuable material.”
A collaboration between Rados International Technologies and MMD was highlighted at MINExpo 2024 where Rados is supplying XRF sensor-based technology for integration into MMD sizingand conveying systems, apron feeders, and feeder systems, including on the Fully Mobile Surge Loader. The Rados sensors have been trialled with MMD apron feeders and sizing-and-conveying systems for ore sorting applications in several locations to date including at Anglo American’ s Mogalakwena platinum operation in South Africa and at several copper operations, where it has a lot of potential.
Annelize Fouchee- Business Development Director at Rados told IM at the event:“ We believe that we have a superior sensing technology which matches
MMD Group Business Development Director Chris Pearson with Annelize Fouchee- Business Development Director, Rados at MINExpo 2024 very well with the robustness and quality of engineering on the MMD equipment. Our rapid bulk ore scanners are particularly well suited to conducting accurate sensing on high throughputs of material in these feeder applications, when mounted centrally under the feeder discharge point in a waterfall sensing position or over a conveyor belt in a material conveying sensing position. Ultimately, customers have a choice when they select a sensor that best matches the application – XRF is elemental-based, which means for a copper ore we do a direct detection of the copper value but we will also be able to see other specific elements of interest such as molybdenum and if there is a high calcium content. Our technology is able to identify the elemental composition at different levels and then accurately make a decision based on the performance requirements of the sort. Other sensors tend to have to use a secondary parameter such as density, or an inferred reading of a characteristic such as light reflection or absorption to then infer a copper value. These inferred readings have large error margins when variable mineralogy is treated and are not as accurate as a direct element detection reading.”
So what is the next step for the Rados and MMD collaboration? Pearson stated:“ We are working on the first commercial bulk ore sorting application but it is not in production yet. Beyond that we are partnering on feasibility studies and pilot plants with potential customers where we are putting forward the joint Rados-MMD bulk ore sorting solution as an option for operations. We work closely with the client to make sure we have the specifications correct for their particular application, in terms of the ore itself but also to match the tonnage throughput. Bulk ore sorting for very high tonnages up to 10,000 t / h or more has only recently started to gain interest and traction, and is very focused on copper mining applications. Top tier miners are asking the right questions and also engaging the major engineering houses to also get involved.”
Fouchee adds:“ In these large tonnage feeder applications, the Rados XRF is analysing a waterfall stream of material – so while the copper ore is in freefall – as the material curtain is opened up in that freefall space, you have more coverage for the sensor as you have a larger amount of surface area available for sensing. Therefore, you are able to see more of the material as opposed to just surface material. The sensor’ s ability to handle a certain throughput is partly based on the conveyor or feeder design, coupled with the FMSL we are confident that rates in excess of 10,000 t / h are achievable.”
14 International Mining | MAY 2025