CONVEYING
Mass transit
Paul Moore gives a detailed update on the mine conveying and materials handling market – from industry consolidation to the latest projects and technology
Conveying remains a core technology for all mining operations – whether that is a short distance conveyor feeding a ROM stockpile, or a long overland installation of many kilometres connecting a remote pit to the processing operation. While they may lack the flexibility of trucking, over longer distances they are the most efficient and the most sustainable way to move material.
Yet in terms of the companies that can design, engineer and supply large scale conveying solutions to the mining sector, it is quite a small world – arguably even
Part of the overland conveyor system at Simandou, designed and delivered by TAKRAF Group
more so that for mobile mining equipment. This is true both of the conveyor systems themselves but also for those companies supplying key components like rollers / idlers and belting.
As such, any major mergers or acquisitions have real significance. One of those took place in December, when Fluor announced the acquisition of the Overland Conveyor Products Group from Denmarkbased FLSmidth & Co. A / S. The acquisition took place via Fluor’ s wholly owned subsidiary, Virta Inc., a US-based provider of design-supply solutions for bulk-material handling across diverse industrial sectors, including mining. Fluor’ s Virta had already announced its acquisition of the RAHCO ® Mobile Stacking Conveyor( MSC) brand from FLSmidth earlier in 2025.
The latest deal encompassed all associated intellectual property, technology, employees, and a select portion of the related order backlog, which will be fulfilled by Virta. It includes a lot of the conveying related assets that FLS had acquired when it took over thyssenkrupp’ s Mining business in 2021.
Virta told IM that the expanded portfolio enables it to further advance energyefficient systems that reduce operating costs, minimise fossil fuel consumption, and lower dust emissions- key advantages over traditional trucking. Overland conveyors provide exceptional operating efficiency and sustainability for transporting bulk materials across long distances and challenging terrain, serving diverse volumes and applications.
“ The Rail-Running Conveyor™ further differentiates Virta’ s capabilities, delivering up to 80 % energy savings compared to conventional overland conveyors through low rolling resistance on steel rails,” said Carsten Hannen, President of Virta,“ These systems cut CAPEX and OPEX dramatically while supporting longer spans, tighter curves, fewer drives, and enhanced sustainability, safety and reliability.”
As mining operations expand and demand for cost-effective, sustainable transport grows, Virta’ s integrated solutions position the company at the forefront of innovation in bulk material handling.
On the subject of the Rail-Running Conveyor TM( RRC), the first-ever production installation has recently begun hauling primary crushed ore at a copper mine in Zambia. According to Virta, this RRC is a 3.25 km retrofit to an existing conveyor relocated by the owner as part of a pit extension project. Tonnage on the RRC has approached the 5,000 t / h design tonnage, allowing for initial performance evaluations. Virta reports that data from this conveyor matches very closely to the parameters that Virta selected for designing its RRC systems. This particular system saves about 55 % of the energy that the conventional conveyor would have required for all demands other than lift. This savings calculation does not account for the additional energy saved by eliminating the two transfer points that a conventional conveyor would have required, or for the compromises needed in retrofitting the RRC to existing belt and drives. Virta also acknowledged the essential contribution of its technology partners at the University of Newcastle, Australia and at Overland Conveyor Company in reaching this milestone.
International Mining | FEBRUARY 2025