rail-veyor® best bulk material handling solution for mining, aggregate, construction
TRANSCRIPT
The Industry’s Green solutionfor generating 20 to 80% in Operating Savings!
What is the Best
Bulk Material
Handling Solution?
You face some
tough choices . . .
Conveyors
• Difficult terrain a problem?
• Too many transfer points?
• Need flexibility?
Truck Haulage
• Expensive to operate?
• Emission concerns?
• Rising fuel costs?
Heavy Rail
• Do you have large
infrastructure costs?
• Need flexibility?
The answer is Rail-Veyor®!
• Company History
• System Overview
• Facts & General Guidelines
• Benefits
• Customer Studies
• Endorsements
• Installations
Rail-Veyor®
Systems (RVS) is founded and first Rail-Veyor system developed at Florida Inst. of Phosphate Research
Risto Laamanen creates Rail-Veyor®
Technologies (RVT) and acquires marketing rights to USA & Canada
Mining giant VALE installs Rail-Veyor®
at it’s Copper Cliff 114 mine
3rd generation Rail-Veyor®
designs are finalized for improved reliability, efficiency and reduced costs
Harmony Gold installs the first commercial underground system in South Africa
Demonstration site near Sudbury is commissioned
RVT restructures and acquires marketing rights worldwide as Rail-VeyorTechnologies Global (RVTG)
VALE sets records in underground mine advancement and production rates with Rail-Veyor®
Rail-Veyor®
is ready to be your material handling solution
1999-2003 2004-2006 2007 2008 2009 2010 2011 2012 2013 2014 - 2015
RVS markets RV technology in Indonesia, RSA, USA and Canada
Risto passes unfortunately
RVTG is recapitalized
System Overview
ConfigurationsDepending on performance requirements Rail-Veyor can be designed in
a number of variations which generally involve one of the below basic
configurations
System Overview
Loading
Loading of Rail-Veyor® can be with a
variety of methods from a simple
overhead hopper/chute, a pan feeder
or a discharge conveyor.
Loading rate and train speed can be
matched to optimize material flow.
System Overview
Rail Cars
New generation lighter weight
structural cars are now available which
allow for increased loading and greater
efficiency.
System Overview
Track Rail & Ties
The Rail-Veyor® track will be installed
on a lightly ballasted route with rail and
steel ties making up the track system.
The route along an existing truck route,
mine drift or over a quarry floor will
make an ideal base for a level ballast
layer to support the system’s light
footprint with a load of only
8 lbs/sq inch.
System Overview
Drive Stations
New generation Drive Stations will be
distributed along the route. They are
designed for simple installation and
can be easily relocated to meet
changing needs.
Drive Station components are
designed for easy change out to
reduce maintenance down time and
improve reliability.
New steel bases require no concrete
System Overview
Drive Stations
New generation Horizontal Drive
Stations are also available where
overhead clearance may be an issue
System Overview
Variable Frequency Drives (VFD)
Drive stations are controlled using
latest VFD technology.
Regenerative drives are available for
loaded downhill operation.
System Overview
Discharge ArrangementMaterial is discharged from the
Rail-Veyor® train by inverting the train
over a dump loop and then re-inverted
and directed back to the loading point.
14 ft. Dia. Loop
System Overview
Control / Monitoring Station
The Rail-Veyor® system will be fully
automated and can be
monitored / controlled from a fixed or
mobile location to be determined with
the customer.
System Overview
Crossings
Rail-Veyor is able to cross under
roads with minimal impact to road
structure by utilizing metal or
concrete box culverts
Rail-Veyor® Facts & General Guidelines
Material Size:Handles material up to 28” minus (.71 m) using std 30” wide car
Annual Tonnages:R/V SS …. Std. System: More than 1M TPAR/V LS …. Light System: 500k – 1M TPAR/V XL …. XL System: Cars with higher sides providing increased car capacity beyond std is needed to achieve higher TPH rates
Haulage Distance: Generally more than 3300ft. (1 km) is preferred
Curve and Grade ability:100 foot (30 meter) radius min horizontally90 foot (27.5 meter) radius min verticallyR-V can run on grades up to 22%. No vibration to cause material rollback.
Maximum Train lengthTechnically there is no limit but it is usually determined by system layout (loops, sidings), and loading
Loading Rate:Recommended speed 5 ft/sec, 3.35 MPH (1.5m/sec) R/V SS … Up to 3,100 tons (2,800 tonnes) per hourR/V XL … Up to 6,000 tons (5,500 tonnes) per hour
Tramming Rate Loaded:Recommended speed 20 ft/sec, 13.4 MPH (6.0m/sec)R/V SS … Up to 12,400 tons (11,200 tonnes) per hourR/V XL … Up to 24,000 tons (22,000 tonnes) per hour
Dumping Rate:Recommended speed 10 ft/sec, 6.7 MPH (3 m/sec)R/V SS … Up to 6,200 tons (5,600 tonnes) per hourR/V XL … Up to 12,000 tons (11,000 tonnes) per hour
Easy Portability ( Relocate / Extend):Ability to install or relocate a drive station in one 8-10 hour shift
Rail-Veyor has a simple light footprint:Only 8 PSI load with small level roadway needed with 4-6” (10-15cm) gravel base 6 ft (1.8m) wide (just track), 15 ft (4.5m) wide (at drive station)
Health & Safety
Benefits• Operates remotely with no on-board
operators
• Little human interaction or need for
sophisticated communication systems
• Provides a healthier environment with
a clean solution unlike trucks emitting
fumes, Diesel Particulate Matter DPM,
or high volumes of noise and dust
• Eliminates vehicle collisions &
accident risks
Eliminate These Risks!
Benefit
Summary• IMPROVED SAFETY . . . SAFETY FIRST!
Automated operation, no onboard operator, inherently safe
• LOW LIFE CYCLE COSTS . . .
Significantly lower operating and maintenance costs vs.
Traditional methods of conveyors or trucks
• GREEN TECHNOLOGY . . .
No diesel particulate emissions
• HANDLES DIFFICULT TERRAIN . . .
Easily operates on grades up to 22% and
multiple curves with as little as 100 ft. (30 meter) radius
Benefit
Summary• LOW POWER USAGE . . .
Electrically powered drive stations with low
electrical usage
• REGENERATIVE POWER CAPABILITY . . .
Drive stations are capable to generate power
during downhill operation
• QUICK DEPLOYMENT . . .
Enables rapid mine development compared
to traditional mining methods
Benefit
Summary• SMALLER AND LIGHTER FOOTPRINT . . .
able to travel under / over roads and water features
with the light rail system
• QUIET OPERATION. . .
More than 50% quieter than conveyors
• LAYOUT FLEXIBILITY. . .
Modular design allows ability to reuse, relocate and extend
the system to follow activity expansion
• HIGH RELIABILITY & AVAILABILITY . . .
Customer support assuring 95+% availability
Benefit
SummaryLow Cost Ease of Maintenance
• Very few adjustments required
• No high tech manpower required
• No mid-life overhauls
- Hub/Wheel bearings and clevis car connections
designed to go 20 year life
- Motors and gear boxes are proven industrial
products designed for heavier and much higher duty
service
• Components designed for easy change out
…. Results in little down time
Underground Mining
Benefits• Enabling technology for rapid mine
development (2 to 4 times faster!)
• Reduced Energy Requirements
• Green Technology …No Emissions
• Reduced personnel
• Reduced Vehicle Collisions
• Reduced Accidents
• Integrates with existing systems
• Expands along the working face
• Reduces demand on ventilation
• Easily travels 22% grades
• 100 ft (30m) horizontal turning radius
Surface Application
Benefits
• Low Life cycle costs …. Lowest OPEX
compared to trucks and conveyors
• Highly efficient steel wheels on steel rail
• Green Technology eliminates dependency
on diesel fuel
• No transfer points like conveyors
• Low Profile - Crosses under roads easily
• Easily travels 22% grades
• 100 ft (30m) horizontal turning radius
• Variable or consistent speeds
• Flexibility to easily relocate or expand
• Eliminates dust & road maintenance issues
3.1 Miles (5km)
1.5M Ton / Year
Underground System
Rail-Veyor® CAPEX
• 45% lower than
Conveyor
• Comparable to
Trucks
Rail-Veyor® OPEX
• Over 80% lower than
conveyor
• Over 90% lower than
trucks
Benefit
examples(customer studies)
Benefit
examples(customer studies)
Large 32,000 T / day operation studied:
• Rail-Veyor® CAPEX significantly better than conveyors!
• Rail-Veyor® OPEX Half of Conveyors …. A third of Trucks!
Benefit
examples(customer studies)
1.75 Mile Haul
3.6 MTPA
1800 TPH
Loop System
Rail-Veyor ® provides
significant savings
(over 80%) in
Operating Costs
compared to trucks
Benefit
examples(customer studies)
Benefit
examples(customer studies)
Less than a 3 year payback!
Benefit
examples(customer studies)
3km Aggregate loop operation at 1.3MTPA studied:• Note no additional manpower required for Rail-Veyor®
as current crusher operator can also operate Rail-Veyor®
Benefitexamples(customer studies)
Rail-Veyor®
Endorsements
Coal Haulage Study On
Rail-Veyor® Material Handling
Versus Conveyors
“ The most surprising outcome of this
research, however, is the
comprehensively competitive
possibilities of the Rail-Veyor® system,
which proved to be the only technology
that was competitive under
every single scenario.”
Rail-Veyor®
Endorsements
37
38
Rail-Veyor®
Endorsements
• International Mining Magazine
• Mining Solutions Journal
• Reuters
• Yahoo News
• Republic of Mining
• Skillings Mining Review
• CIM Magazine
Rail-Veyor®
Installation Summary Sudbury Demo
& Test Site
Copper Cliff Mine,
114 Sudbury
Phakisa Mine,
South Africa
Rail-Veyor®
Installations
Rail-Veyor® Sudbury
Demonstration & Test Site
• 750 m test loop with over 25,000 circuit cycles completed
• Dump loop with re-invert and re-load capability
Rail-Veyor® Installations
Vale Copper Cliff Mine 114 Ore Body Commissioned in 2011 Installed in 6 months!
• 1 km haulage distance
• Shuttle style operation
• 15% gradient uphill haul
• 1 train 432 ft (132m) long
• 26 Drive Stations (100HP x 2 motors)
• Loading Speed – 0.25 to 0.45 m/s
• Dumping Speed – 1.5 m/s
• Travel Speed – 3 m/s
• 15,000 RVT hours injury free
• Achieved 400-470 ft./week of drift development …
2 to 4 times faster than traditional methods!
Rail-Veyor®
Installations
Some of the Vale
Project Team were
interviewed about
how Rail-Veyor®
was used at Vale’s
114 ore body.
Rail-Veyor® InstallationsSome of the Vale Project Team were interviewed about how Rail-Veyor®
Material Haulage System was used at Vale’s 114 ore body.
Alex Henderson, Vale, GM, Underground Mining Technology
“The key benefits of the Rail-Veyor® material haulage system are more in terms of the ability to integrate the solution into our development process for high speed development and significantly reduce the lead time to production. Lead time to production for any project is extremely critical for the return on investment for the project. So if we can develop twice as fast as we currently do to bring an ore zone into production so rather than 4 years of pre capital expenditure before we bring in cash and we can reduce it that to 2 years it has a huge impact in terms of the return on investment.” “Things have progressed extremely quickly with respect to building the facility and installing the Rail-Veyor® System and ultimately how we’re going to use the Rail-Veyor® for high speed development and high speed production. Everything from building to installation has gone very well. All our timelines associated with the project and the building of it has gone extremely smooth all the targets and timelines in respect to various components have been met.”
Kate McLaughlin, P.Eng., M.Sc., Vale, Manager Technical Systems Development Canada“The thing that impressed me most with the Rail-Veyor® here at 114 ore body was how quickly it was constructed. There has been a tremendous amount of work done engineering all the different components,and because of that they go together very quickly and construction happens much more rapidly than I ever thought would be possible. Because of that I think the real benefit is your ability to get into production and development much quicker than with some other historical systems.”
Rail-Veyor® InstallationsSome of the Vale Project Team were interviewed about how Rail-Veyor®
Material Haulage System was used at Vale’s 114 ore body.
Peter Golde, Vale, Manager of Mines Research & Development
“What the Rail-Veyor® represents to Vale, as an opportunity, is for us to begin changing the way that we think about designing and building new mines, as well as how we would deal with the very deep ore bodies, the ever increasing depths to which we are mining today. It represents a possibility, an opportunity, for us to radically simplify those new mine designs, and to eliminate many of the typical installations that we need to put in underground, that require creating huge openings, say for large underground crusher installations, it eliminates for us the need to put in, in many cases, ore passes to move the ore to the bottom depths of the mine where these crusher installations are.”“Rather than having to position other intermediate ore handling systems, to move the ore from where the ore bodies are to the location where the shaft is situated which in many cases could be kilometers away from where the shafts are located. We now have the ability to take the principle ore handling system and move it directly to where the ore is located which is something we’ve never been able to do previously.”systems.”
Harmony Gold Phakisa Mine Project 2005
South Africa
• 4.7 km long tram one way
• Operates as “Bicycle Chain” style with 3 trains
• Slight downgrade loaded haul between two shafts
• 4M Tonnes /year (300 TPH)
Harmony, headed by CEO Graham
Briggs comments about Rail-Veyor® in
Mining Weekly 2013
“Phakisa's technological innovations
enable the mine, a deepening project
which is ramping up to full production in
2014, to extend 2,4km below surface.”
“The Rail-Veyor® is cheaper and safer
than using trucks or conveyor belts to
transport ore, since electricity
consumption is minimal and it is
driverless. And it is simple to use, and
easy to repair and maintain.”
Questions?
What is your material handling challenge?
Let us provide you a
Green $$$ Cost
Saving Solution …
A Rail-Veyor® Solution
Tel: 705 682 0450
Email: [email protected]
Notes