Koch Solutions’ new steep-angle conveyor system handles steep inclines with ease and grace.
Trucks have long been the go-to solution at high tonnage rates for bringing ore from the bottom of an open pit for processing.
Standard conveyor systems are also used at times, but extreme slope inclination has proved a challenge to the wider adoption of such systems, especially on deep-pit projects. However, globally based material handling technologies company Koch Solutions saw this situation as an opportunity to innovate and find a new way to economically mine at depth.
Koch Solutions (Australia) chief executive officer Thorsten Roettgers said that as existing mines become deeper, current methods of extraction are making them uneconomical to mine, with additional resources remaining untapped as a result.
That’s where the IBEX steep-angle conveyor comes in.
“The IBEX was developed to overcome this challenge and open new horizons for mining at depth,” Roettgers told Mining.
“Development of new mines is becoming more expensive and is taking longer to realise. The IBEX adds an additional case to mine continuation.”
What is the IBEX?
The IBEX is a steep angle conveyor system that, according to Roettgers, addresses the limitations of current technologies and provides continuous ore delivery from the pit to the process plant.
The development of the IBEX focused on overcoming one of the critical limitations of the traditional conveyor system: belt strength.
“With the IBEX system, multiple drives are positioned along the system, significantly reducing the belt strength requirements while at the same time providing drive redundancy and the ability to vary operational performance,” Roettgers said.
A conventional conveyor system using rollers requires significant power to overcome the belt to roller indentation forces. By contrast, the IBEX base belt uses steel rail and wheel technology.
Roettgers said that by removing the rollers and using steel wheels on rails, the IBEX significantly reduces the friction of the system, which in turn reduces the installed power consumption.
“Because the belt is also not continually travelling over rollers the life expectancy is significantly increased,” he said.
The IBEX uses side wall conveyor technology designed to ensure material stays on the belt even with inclinations above 20°. Roettgers described the side wall conveyor technology as a proven, practical technology, modified and enhanced specifically for the IBEX by Koch Solutions. Between the side walls, cleats are used at intervals to prevent the material from rolling back as the belt progresses up the incline.
“The real value of the IBEX comes from the operational cost savings in comparison to truck haulage, full electrical operation using existing proven technology, long component life, which can all be summarised into cost and emissions reduction for the mining community,” Roettgers said.
Given the IBEX system is new to the resources world, Roettgers said it is still undergoing feasibility studies for use in deep mining.
“The current use case for this equipment is in bulk material movement,” he said. “The process required elevation steps of 100m at a time, which was not achievable with any other type of materials handling equipment.
“The implementation of the IBEX in this process has enabled the project to reach realisation.”
Roettgers’ belief in IBEX was backed by the company’s long-standing reputation for reliability and performance.
“Clients choose Koch Solutions because they want the confidence that when they push the go button, the machine will perform and operate at name plate day-in, day-out,” he said. “Our heritage is testament to this, with over 200 machines installed in Australia and thousands around the world.
“For a new technology such as the IBEX, we developed a pilot plant and tested and developed the componentry over different trials and use cases before commercial operation.”
Koch Solutions views IBEX as a high-value, critical element in the future of the sector.
“The future of pit-to-port will be highly customised for end client requirements and involve seamless material movement,” Roettgers said. “This will mean a piece of ore dug in the mine will be traced all the way to the ship with full measurement of its grade, quality and cost to get there.
“Companies have spent millions of dollars improving existing technologies to meet environmental and cost targets, where the IBEX solves them with simplicity.”
This article appeared in the Spring edition of Mining Magazine.
