Koch Solutions has designed a conveyor system that has the potential to unlock deeper mines and reduce the need for truck fleets.
Gold was initially discovered in Kalgoorlie in the 1890s, forever transforming the region.
Prospectors flocked to the region, which, according to Bill McKay, Ian Lambert and Shige Miyazaki from the Australian Geological Survey Organisation, had become one of the world’s major centres of sustained gold mining.
Mining this gold required deep shafts, machinery, and treatment plants. Tents were soon replaced by towns as confidence in the long life of the mines increased.
Fast forward more than 100 years, and these pits have become some of the largest and deepest in the country.
Koch Solutions head of sales Luke Bennet told ABHR that Australian mines are becoming deeper, raising questions about the profitability of ongoing operations.
“If you look at some of the gold mines in Western Australia, they’ve been mined for decades,” he said. “They drill and find more ore, which leads them to go deeper and deeper.”
“Eventually, they reach a point where they need to start considering whether they go underground or continue as an open pit as it becomes less viable to move the ore out of the pit.”
This problem is what led Koch Solutions to develop the IBEX steep-angle conveyor system.
Traditional conveying systems are limited by the tension that can be applied to the belt. When working with steep inclines, conventional belt system tensions would exceed practicality.
The IBEX system uses multiple drives along the length of the conveyor, along with rail running technology that significantly reduces the friction losses typically seen on traditional idler conveyors. This friction reduction reduces the installed power requirements to overcome friction losses and increases the belt’s longevity.
Bennet said the system uses a flat base, side-walled conveyor system, which at angles above 25 degrees employs cleats to prevent the material from rolling backwards.
“The advantages over traditional truck-based haulage in deep mining are the removal of the energy consumed by the truck while driving empty,” he said.
“There are also significant advantages [compared to] truck haulage over long distances due to tyre heat restrictions. The deeper a mine, the more trucks are needed to maintain production, requiring additional investment and personnel, including operators and maintainers.”
Proven technology
The IBEX system emerged when Koch Solutions identified a gap in the market. Mines were becoming increasingly deeper, and mine operators were facing environmental, social, and governance (ESG) constraints.
After undergoing several digital designs, the company developed a pilot plant at an iron ore mine in Austria to serve as a proof of concept. This plant underwent several tests and trials during the scaling-up process to ensure it was fit for purpose.
While this was happening, Koch Solutions investigated the market to find suppliers that could deliver standard equipment, to ensure the system was easy to maintain and operate.
Bennett said the company is proud to be a technology-driven business.
“Even though we could keep doing the same replicatable projects, for us, it’s about finding the next groundbreaking technology for the sector,” he said.
“We put it through a lot of research and development. We worked with belt suppliers on what kinds of belt we needed, how they splice, and interacted with the market to find out how we could bring standardised conveyor components into its design.”
“It’s not reinventing the wheel – it’s industry standard equipment. Using a known entity reduces risks on a project.”
The mining industry has shown great interest in the IBEX system, with several orders already placed. Some mines have also engaged Koch Solutions to study the viability of incorporating the technology into their sites.
One reason behind this surge in interest is the IBEX’s ability to reduce reliance on trucks. By doing so, a mine can remove truck-person interactions, which has a significant safety benefit.
Bennett said that although truck fleets are becoming increasingly automated, personnel are still required to maintain the equipment, and high-traffic areas are still safety concerns for personnel interactions.
“The IBEX removes all of this and simplifies it into a single asset,” he said. “If the operation reduces its throughput, the system can shut off drives or operate at a lower installed power draw, making the system very flexible for the available power and production requirements.
“It can also be operated on renewable power. Even though there is rubber used in the installation of the conveyor belt, the expected life of the belt has significant wear advantages over truck tyres.
“Removing diesel usage and tyre usage of a typical seven-year truck life reduces emissions as far back as manufacturing.”
Koch Solutions aims for the IBEX system to grow as a mine does, with a lifespan of up to 25 years. It can scale up to 16,000 tonnes per hour, unlocking productivity for mines across the spectrum of sizes.
Bennett said it is the first time that everyday technology has been used to build such a high-capacity system.
“The IBEX system unlocks potential for existing mines, allowing them to go deeper,” he said.
“It has the power to render conventional truck fleets obsolete. It doesn’t just move materials; it moves your entire operation into a future where efficiency soars and limitations are left far behind.”