Mining engineering company Tenova Takraf’s modular overland conveyor system can be moved once its purpose is fulfilled. It can easily be transported in assembled state by truck and placed by a small crane.

This significantly reduces the labour and time required to build a conveyor system. It can be relocated with ease, bolstering the case for investment in the system. Capital spent on conveyors is not lost when the material transport route changes.

“We wanted to change the paradigm around overland conveying and ensure that the costs for this system become an investment for the mining company that it can reuse.

“The system was developed to tackle the problems our clients face daily, including high capital costs, a lack of flexibility of infrastructure and the long time spent building the infrastructure,” says Tenova Takraf Africa MD Riccardo Tonini.

This conveyor system will also enable disjointed orebodies or smaller deposits to be exploited more efficiently, as the modular components of the conveyor system can be picked up and placed at another site, with less labour and within a short predetermined time span.

The conveyor can be deployed to lengthen existing overland conveyor systems and conforms to the safety requirements of overland conveyor systems, including emergency shut-off cables (called pigtails), cable racking and firewater pipes, says technical collaborator and 4-PLY project execution MD Norman Collier.

“The components of this modular overland [system] are standard, which reduces logistics challenges and can easily be replaced. More modules can be added to lengthen conveyor systems, such as when the mine face retreats, or to efficiently process ash heaps.”

A key benefit of the system is that the modules do not need to be transported far because the concrete bases of the module can be cast within a small concrete casting factory close to where they will be deployed. This enables centralised quality control for the modules, says technical collaborator, concrete-mould developer and Allasso Construction owner Mark Sullivan.

“Our clients are increasingly asked to demonstrate the benefits that local communities derive from mining operations. “The system enables mines to establish cast concrete start-up factories, which not only helps to develop skills and local employment, but is also enterprise development within these communities,” says Tonini.

Further, the concrete bases of the modules can also be cast using different concretes that can withstand different conditions, such as a wider base for use on softer soils or alternative-grade concretes to withstand acidic conditions, notes Sullivan.

“The system aims to enable our clients to mine competitively amid severe pressures on – and significant fluctuations in – the mining and resources industries. “Our whole design concept was based on addressing specific challenges around overland conveying that our clients face, including high costs, inflexibility and long construction timeframes.

“With this overland conveyor, our clients can have the efficiency of an overland conveyor system, while retaining some of the flexibility afforded by transporting the materials by truck and while having lower operating costs than trucks and lower capital costs than conventional conveyor systems,” emphasises Tonini.