Mines are continuously being challenged to rethink how to shape their operations to be more sustainable and profitable. It is for these reasons that diversified engineering group Metso has launched its “comprehensive” in-the-pit solutions (ITPSes) which seek to optimally improve the entire mining process from design to selection of machinery and production output.

“The mining industry is continuously exploring not only new ways to mine at lower cost, but also new sustainable methods, technologies and systems. Transportation of ore and waste is one of those areas of an operation that can account for between 50% and 60% of the operating cost of mining,” notes Metso ITPS director Erik Isokangas.

He points out that, if truck haulage use can be reduced, significant savings can be achieved by mines. Isokangas elaborates that ITPSes are advanced options for conventional production processes where truck haulage is used.

“With these solutions, it is possible to reduce overall costs by between 15% and 35%. The savings mainly come from improved energy efficiency resulting from well-planned conveying and reduced maintenance and labour costs,” Isokangas states.

ITPSes include concept and feasibility studies, design, engineering, equipment, systems, procurement, commissioning, maintenance and operation. ITPSes can also be connected to Metso’s tailored life cycle services contracts.

Isokangas adds that Metso can supply fully mobile and semimobile in-the-pit crushing systems, along with conveying and materials handling solutions to cater for different demands.

Further, he comments that a mobile crushing system removes the reliance on truck haulage. An excavator loads material directly into the hopper of a Lokotrack mobile crushing plant and crushed rock is then transported to an in-pit belt conveyor by means of mobile Lokolink conveyors. The conveyor carries crushed rock from the Lokotrack to a processing plant or waste dump.

When blasting is performed, the Lokotrack and Lokolink conveyors move to a safe distance. After the blast, a wheel loader cleans the quarry floor and the Lokotrack plant moves to the new muck pile. “The mine’s operations resume with minimal production downtime,” Isokangas highlights.

Additionally, he notes that a semimobile crushing unit reduces the distance for truck haulage. Metso’s units are designed to be moved as a single device or disassembled into four to six smaller modules mounted on skids for easy transport. Isokangas remarks that, typically, these crushing systems are moved every few years.

“This method leverages the flexibility of trucking operations, while reducing the cost of long-distance haulage. The main applications are in operations where the mining is selective, where the orebody is heterogeneous or for capacities above 3 000 t/h for hard rock materials,” he concludes.