IPCC
necessary such as in a tails deposition application, we usually have a
spare stacker and stacker feed conveyors which effectively provides a
redundant system, particularly if there are an extra couple of spare
SUPERPORTABLES ® as well. Since you are adding and removing
SUPERPORTABLES ® in and out of the string TNT states that they can
usually arrange the stacking solutions in a manner that has the spare
stacker ‘share’ SUPERPORTABLES ® and provide a redundant system with
very little extra equipment making these systems extremely cost effective
and versatile.”
An example of redundant stacking systems depositing tails on a multi-
lift retreat stack is the redundant system operating at Ma’aden Phosphate
Company in Saudi Arabia. This system has dry stacked 35,000 t/d of
tailings since 2010 on a pad that has five lifts, each 10 m high, with an
eventual footprint of 1,200 m x 3,200 m. TNT is currently supplying the
third expansion for the dry stack tailings system. “This is an example of a
completely stable and safe tailings pad that has saved tremendous
amounts of water, and what we see as the new standard for tailings
systems.”
Each of these latest Semi-Mobile units will be
utilised to the full, processing overburden at a rate
of 5,500 t/h, whilst reducing material from up to
1.5 m down to 300 mm. With parts supplied from
the UK, South Africa, China, India and Thailand,
this ambitious refurbishment and new build
project brings together MMD companies and
expertise from around the world.
“MMD deliver good performance and
reliability,” said Payungsak Jaikham, Project
Coordinator of ITD. “We received a very
competitive price, and we are looking for a long-
term relationship with MMD. We know they can
support us.”
FLSmidth forging new IPCC futures
Arguably now having the most comprehensive
IPCC offering since its acquisiton of Sandvik
Mining Systems in 2018 and with a portfolio now
covering everything from primary crushers to
fixed, semi-mobile and fully mobile crushing
stations, overland conveyors, shiftable mine
conveyors and spreader systems plus innovations
such as the EcoTails (co-mingling of crushed waste
rock and dry tails) and the Hybrid Apron Belt
(HAB) feeder, FLSmidth now has activities across a
number of different project types and activities in
different commodities and regions, Branco Lalik,
Director Process Line Management Mining
Systems, told IM.
First off the company is in discussions with a
client in Brazil about different scenarios -
including trials and testing - on how to utilise the
FLSmidth ABON sizer technology in operations for
various material types found in iron ore, including
harder rock types, which previously have not been
suitable for processing by any roll crusher type.
"However, with our extensive sizer tests and
operational experience from other hard rock
applications we see this as a great technical
opportunity. We are very confident that our sizers
According to Emerson, it is encouraging to see clients starting to engage
TNT directly much earlier in dry tails stacking and IPCC waste stacking
projects, which is key. “It is logical and easy to understand the advantages
of conveyor haulage versus trucks when considering the environment,
safety, water usage, carbon footprints, dust and OPEX. Making the
paradigm shift is more difficult because trucks are ‘easy’ and a known
quantity. However, by involving the OEM equipment suppliers early in the
design, the optimum use and application of their systems is better applied.
In reality, the CAPEX is generally similar, the OPEX is half or less and the
resulting cash flow/IRR are much improved when conveyors are maximised
in the mining process. Again, it is logical and common sense. With
conveyors as flexible and mobile as TNT’s SUPERPORTABLE ® systems,
many of the advantages of the trucks disappear. Water, CO 2 , dust and
labour will force us to all look at the best haulage systems for waste, ore
and tailings that are better for the environment and the bottom line. This is
where TNT sees the future of mining projects, and where we believe the
SUPERPORTABLE ® technology will excel due to the mobility, flexibility and
versatility of the design.”
can perform well in these
manifold applications at
high capacities in the
challenging
environment.”
Moving to China,
FLSmidth is having
ongoing business
development discussions
with JV partner Northern
Heavy Industries Group
(NHI) about opportunities based on their crusher
portfolio on an application case-by-case basis to
utilise the JV (NHI-Fuller Mining) in the best
possible way. Currently the focus is more on
secondary crushing applications with cone
crushers but could include the consideration of
larger gyratory crushers in fixed or semi-mobile
crushing stations. Lalik stated: "This will depend
on the expectations of our customers in terms of
the required features of the crusher. For instance,
applications in not too challenging environments
in terms of materials to be crushed such as coal,
lignite or in non-abrasive waste materials may
certainly be more suitable, where there is no need
for a top service crusher and other special
maintenance features."
On agreements with major Tier 1 miners, the
recently signed Global Framework Agreement with
Rio Tinto is not only based on equipment deals
but also on new developments and the whole R&D
area in mining. "There has been a regular, active
dialogue and bilateral exchange of information
between Rio Tinto and ourselves since this
agreement has been put in place. We have had a
very positive trend and development at FLSmidth
in the last two years with key accounts such as Rio
Tinto and Goldcorp/Newmont regarding close
cooperation in order to realise large mining
projects together and we are certainly glad to be
part of it.”
FLSmidth semi mobile crushing stations, part of
an IPCC solution provided to Barmer Lignite
Mining Company Limited (BLMCL) in Rajasthan,
India
The new HAB system is still in the development
phase. Lalik states: "The main focus of our work is
to look at how we can cover multiple applications
with the same concept whilst keeping the
technical and economic advantages of the HAB at
the same time. With introducing different
materials for instance, one needs to look at the
material flow capabilities, the durability of the
feeder and its scalability to address different feed
capacities in particular. At the moment we have a
couple of solid enquiries in iron ore for medium
capacity levels. We will put a new reference for the
HAB feeder into operation soon."
Finally on actual IPCC references and projects in
the offing, in Peru FLSmidth was selected as a
preferred supplier by a major copper miner for a
high-capacity semi-mobile crushing plant. Further
down the line in northern Brazil in iron ore a new
project is now in the execution phase with two
complete IPCC systems each with 5,000 t/h
nominal capacity consisting of two semi-mobile
crushing plants and five overland conveyors in
total with a length of more than 5,000 m. The
longest conveyor is around 1,500 m long. “It has a
difficult geometry with an inclined section, where
the system requires significant power and a
MAY 2020 | International Mining