Mineral Processing Solutions (MPS) and Telestack partnered with an Australian mining operation to meet its production goals.
When an Australian mining operation approached Mineral Processing Solutions (MPS) about its plans to bolster its production on-site, they had a clear goal in mind.
The client was looking to achieve a 1000tph feed rate on its site, boosting the project’s efficiency.
Mineral Processing Solutions began collaborating closely with Telestack, discussing potential options to deliver the required production rate.
The two businesses not only met the customer’s desired goal, but they exceeded it significantly with a feed rate of 1600tph. According to those involved, the new feed rate shaved 50 minutes off the loading time per cycle, drastically increasing the project’s efficiency.
Mineral Processing Solutions area manager Adam Dever told ABHR the project was a significant milestone.
“It’s the proudest moment of my professional career. I’ve been in mining for a long time, but the achievements of this project are a career highlight,” he said.
“This collaboration has resulted in substantial cost savings for the customer and minimal downtime for their plant, thanks to the high-quality structure, motors, and gearboxes that Telestack provides.”
Smart solution
The project required an innovative solution for material feeding and stacking, as the coal was destined for markets in Asia. The product was processed on-site before being transported via truck to the train load-out facility, where it would reach the Port of Brisbane and then go to the Asian markets.
To meet the customer’s desired goals, Mineral Processing Solutions and Telestack designed an innovative system comprising several components.
The system featured a Telestack HF 24T Hopper Feeder, an HF 10T Tracked Hopper Feeder, two TC 424X Tracked Stockpiling Conveyors and three TC 624R Tracked Radial Stockpiling Conveyors.
“We seamlessly integrated our equipment with existing on-site infrastructure to enhance automation and user-friendliness. The equipment has various applications within the Australian mining operation,” Telestack international sales manager Philip Waddell said.
“The ability to integrate the equipment into both mobile and static applications and to supply the equipment quickly with Mineral Processing Solutions stock in the country was also a factor in winning this project.”
The Telestack equipment has improved the Australian mining operation’s project from the initial stacking stage to the final load-out. In the initial stage, where the coal is stacked directly from the impact crusher, a TC 424X Tracked Stockpiling Conveyor and Telestack Tracked Radial Stacker TC 624R help stack the material.
The TC 424X takes the bypass material (50mm-plus) before it enters the impactor and creates a conical stockpile. This creates a greater stockpile capacity compared to using just the capacity created by the bypass discharge conveyor. The TC 624R stacks the coal from the crusher’s product belt, able to stack up to 10,000m3 of material without moving.
When the coal progresses on-site, it is fed through the HF 10T Tracked Utility Hopper Feeder, which regulates the material flow. The HF 10T Hopper Feeder works with a TC 424X to feed the correct material into the Coal Handling Preparation Plant (CHPP) intake at a height of eight metres.
Once the finished material is processed through the CHPP, two TC 624R radial stackers stockpile the product to be ready for train load-out (TLO).
During the train load-out process, where the coal is brought to the stockyard via truck, the HF 24T Hopper Feeder feeds the TLO system. The high-capacity system can handle up to 1600tph at 35 hertz, with further capacity to run at 55 hertz if required. Its 70-degree tapered hopper, which uses a heavy-duty apron belt feeder, regulates the feed to the TLO.
“Our engineering capability, marked by a dedication to precision and quality, played a pivotal role in this project,” Waddell said.
“At Telestack, we believe that the key to success lies in the fusion of state-of-the-art technology and an unwavering commitment to delivering exceptional results.
“This project exemplifies our ability to create innovative solutions that not only meet but exceed our client’s needs, a testament to our engineering capabilities and dedication to pushing the boundaries of material handling excellence.”
Since the Telestack system became operational, the customer estimates it has saved millions in engineering and construction costs.
The customer said Telestack exceeded their project expectations, while Mineral Processing Solutions had become their benchmark for aftersales service.
The new system has seen the customer improve operational flexibility while maintaining high throughput rates and lower operational costs.
Mineral Processing Solutions has locations across Australia to support customers with aftersales service. The company maintains a head office in Perth and facilities in Adelaide, Darwin, Newcastle, Goodna and Melbourne
It is another example of how Mineral Processing Solutions has come to specialise in plants with up to 3000 tonnes per hour throughput rates. The company offers process engineering, equipment selection profiling, individual component supply, complete process turnkey equipment solutions, and monitoring and efficiency consulting.
“We are thrilled to offer our top-notch after-sales service and readily available spare parts to ensure the customer receives the utmost attention and maximises uptime and efficiency,” Dever said.
“It’s a testament to the power of partnership and quality solutions coming together for outstanding results.”