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Challenges

For asset owners and operators of facilities that move, store, and process materials, good performance always means achieving the lowest cost per tonne over the life cycle of the structure. But the mining, beneficiation, and transport of commodities has never been more challenging.

Industrial operations that rely primarily on bulk-materials-handling equipment are struggling to meet ever-increasing demands for safety, reliability, performance, and productivity. Doing more with what you have—or in some cases, even with less—becomes possible only with customized, innovative, and optimized solutions that can drive your assets to world-class levels of performance.

From hard ores to sticky materials; from powders to temperature-dependent substances like oil sands and asphalt; it's about understanding two main drivers: the underlying characteristics of the material, and the complex interdependencies of the facility's handling equipment.

To be competitive, materials-handling facilities must be designed for today’s products...in today’s marketplace. Innovative technology, progressive computer-aided designs, and process tools are the keys to getting and keeping a competitive edge. All these must come together, in the best possible way, to create systems that are optimized to the specifications of the facility and the characteristics of the material it handles.

Capabilities

Comminution

Correct equipment selection, sizing, and layout all play a key role in the design of comminution circuits. A complete process design capability, including comminution optimization and mineral processing, is an integral part of the mining and prepreparation of ore.

Conveying systems

Conveying systems are the mainstay of bulk-materials handling. Today, an emphasis on safety, environment, energy efficiency, operability, maintainability, and cost effectiveness informs design. High capacity, complex, long, overland conveying systems, as well as any in-plant conveying equipment, must be easily obtainable options for successful operations.

Stockpiling and storage systems

Reliable, effective homogenization and ore-blending knowledge is essential for efficient stockpiling and reclaiming. Dependable, blockage-free storage vessels are also critical to most plant processes. You need the benefit of a deep knowledge of stacking, reclaiming, and storage systems from consultants and service partners with experience in the design and construction of complex storage, blending, and homogenisation facilities, right through to silos, bins and hoppers.

Loading and unloading facilities

Knowledge of loading and unloading facilities and the interaction between components is essential to avoid spillage problems and sequence overlaps. Facilities must be composed of various elements—rail-and-truck dumping stations, as well as ship loading-and-unloading facilities—that need to be effectively integrated.

Dust control

Human health and safety and environmental sustainability must always come first. Never is there a one-size-fits-all solution when it come to dust control.

Discrete element modeling (DEM)

DEM analyzes material flow, identifies potential issues, and verifies that design solutions do what they’re supposed to. It provides techniques and opportunities to optimize the function and performance of transfer chutes, showing how to maximize throughput, prevent build-up and associated blockages, and minimize impact and wear on interfaces.

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