Material Handling Solutions

FLSmidth’s RAHCO® Mobile Stacking Conveyor Systems will increase your flexiblility, not your operating costs.

MSC and Spreader

Mobile Conveying

Moving beyond conveying

MSC and Spreader

The first RAHCO® Mobile Stacking Conveyor was supplied to Pacific Power & Light in 1981. At a capacity of 800tph, this system was used to stack and reclaim coal in Washington State, USA. This was the start of a revolutionary conveying technology that would disrupt the material handling industry.

PPL MSC

As part of FLSmidth’s One Source equipment solutions, RAHCO Mobile Stacking and Conveying systems are an integral part of our complete material handling flowsheet. RAHCO Mobile Stacking Conveyors have helped realize operating cost savings across numerous industries, such as coal, iron ore, gold, and copper. FLSmidth has also engineered tailored solutions for dry tails stacking, permanent and reusable heap leach pads, and overburden handling applications.

MH Flowsheet

Dry Tails Stacking

Two important issues that every mine must deal with are managing water requirements and waste material disposal. FLSmidth’s RAHCO Mobile Stacking System was chosen to overcome these issues at Karara Mining Limited’s Karara Iron Ore project in Western Australia.

A dry tails stacking solution allows for water to be reclaimed back into the mining process, thereby reducing the costs associated with additional water sources. Vacuum filter presses reduce the waste tailings moisture content down to about 15%. FLSmidth is a leading supplier of automatic and belt filter presses that are optimized to produce a conveyable, low-moisture filter cake.

The resulting filter cake is then conveyed to the waste stacking area via overland conveyors. At the Karara site, an area 2 km x 2 km (4 km2) has been allocated for tailings storage. By comparison, should a more traditional pond storage system be utilised, an area of around 52 km2 would be required to store the tailings the Karara project will generate. (The area required for such a pond storage system is based on a 3m deep pond. For a fully-lined 6 metre deep pond, the space requirement would be halved. However, even at 6 metres deep, the total area required is significantly more than that allocated for the dry storage system tailings).

FLSmidth’s RAHCO Mobile Stacking system offers a number of benefits for the project and would go a long way toward Karara meeting its water reduction target of 30 percent.

The client stated regarding the cost savings, “We examined multiple options, finally arriving at the mobile stacking conveyor solution as more environmentally appealing, much less water dependent and ultimately lower cost for our customer.”

Karara Spreader

Overburden Handling

FLSmidth was chosen by PT Adaro Energy, owner of Indonesia’s largest single coal mining operation, to supply an innovative crushing and conveying system. Over several years, FLSmidth and PT Adaro worked closely together to develop the mine plan and equipment solution that fit future expansion plans. With a history of increasing production every year, up to 1 million bank cubic meters (Mcbm) of overburden is moved each day. FLSmidth’s crushing and conveying system will account for close to 10 percent of the mine’s overburden production.

FLSmidth equipment at the Tutupan site includes two ABON® sizing stations with apron feeders that feed onto a series of four overland conveyors. Material then arrives at the overburden stacking area where it is stacked by a mobile stacking system equipped with a spreading conveyor. The crushing and conveying system is designed to handle overburden at 12,500 tph.

This system incorporates the dumping of overburden hauled by trucks into crushers at the pit perimeter, and conveying the overburden to a disposal area some 6 km distant. This will significantly reduce the overburden haulage requirements at the mine, saving manpower and fuel, and reducing truck fleet size. This combination of FLSmidth technology boosts the efficiency by which the large amount of overburden is transported and helps secure Adaro’s unbroken track record of continuous growth.

Tutupan Spreader

Heap Leaching Applications

Grupo Mexico has found success with RAHCO Mobile Stacking Systems at the Buenavista del Cobre mine site. Opening in 1899, Buenavista del Cobre, formerly known as Cananea, is one of the oldest mines in North America. In an effort to improve the mine’s efficiency, a RAHCO Mobile Stacking System was put in operation in 1995. Since that time, three more stacking systems have been installed, one in 1997, and the latest two systems starting operating in 2012. A permanent heap leaching system is used to extract the copper ore. The ±300mm (15 inch) rock is stacked in lifts up to 30m (100 feet) deep.

The RAHCO Mobile Stacking System has realized cost savings in several areas when compared to haul trucks. Only one worker per shift is required to operate a RAHCO Mobile Stacking Conveyor. Haul truck costs are eliminated in regards to maintenance, tires, operators, and diesel. In addition to the operational savings, overall risk is reduced since there is no chance of haul truck traffic accidents. Training workers to operate a RAHCO Mobile Stacking Conveyor is also significantly less complicated than training a haul truck driver. Lastly, environmental impact is greatly mitigated with shorter haul truck travel, reduced haul truck exhaust, and lower dust emissions.

Buenavista del Cobre

Cost Savings for Your Mining Operation

FLSmidth’s RAHCO Mobile Stacking Systems are proven to reduce operating costs, minimize environmental impact, and mitigate operational risks. If you would like to learn how FLSmidth’s technology can be tailored to improve your mining plan, please email mhna@flsmidth.com.