In the dynamic world of mining, where efficiency and sustainability are prioritised, Railveyor emerges as a game-changer. 

The emphasis on productivity alongside decarbonisation and energy-efficiency is clearly evident in how engineering, procurement, and construction (EPC) firms plan new mining projects or expansions. They increasingly place the materials handling system at the centre of their design, considering not only the capital cost of the system and its installation, but also its operating cost and flexibility over a mine's life. This has brought hybrid technologies like Railveyor into the spotlight.

Best of both worlds

Railveyor's system leverages the advantages of light rail and conveyor technology, improving levels of automation and safety. Its robust design offers optimal flexibility, delivering strong reliability for streamlined operations. The system consists of a series of interconnected steel rail cars forming a continuous train. The train runs on tracks that can be installed on a lightly ballasted substrate. This avoids the high cost and fixed nature of concrete foundations required by conveyors.

Railveyor's versatility allows it to match the technical specifications of any new project or expansion, integrating readily into the project plan. Central to the system's efficiencies are the lightweight cars running on steel tracks for the lowest rolling resistance.

The Railveyor system is based on individual steel rail cars that make up a train, connected to each other with steel clevis assemblies and flexible flaps that prevent material spillage. Rather than using a locomotive, the train is driven by automated drive stations – each comprising two horizontally oriented wheels powered by electric motors. These propel the train through contact with the side plates on each car.

Flexible for turns and gradients

The robust concept allows for optimal design flexibility, delivering strong reliability for more productive and streamlined operations. Traditional conveyors typically need a turning radius of at least 500 meters, but Railveyor can navigate turns as tight as 30 or even 20 meters. Railveyor handles gradients of up to 30%, enabling more direct, cost-effective routing. This also reduces the need for costly infrastructure modifications over time.

Automation and safety

Digital technology boosts the system's efficiency and safety. The company's proprietary TrulyAutonomous™ system enables full automation through advanced software. This allows daily operations to run without human intervention or the need for personnel to be nearby – streamlining material handling, increasing production and placing safety at the forefront.

TrulyAutonomous™ software communicates with variable frequency drives (VFDs) to control the 75kW motors in the drive stations with precision timing. Speeds, torques, currents and other variables related to the operation of the train can be centrally controlled and monitored. To further enhance power efficiency, the drive stations can even regenerate energy when the train moves on a decline. 

Healthier environment

The system eliminates diesel fumes in underground operations, significantly reducing ventilation requirements. This helps align with the standard operating procedures and environmental benchmarks set by EPCs, as well as by government and other regulatory organizations for mining organisations. In this space, hybrid systems have gained prominence by combining the strengths of proven technologies while effectively overcoming their limitations.

Growing footprint

Railveyor's performance has been proven in the field, and is being specified in a growing list of feasibility studies for new or expanding operations. At Agnico Eagle Mines' Goldex complex in Canada, the system has allowed the mine to reduce material handling operating costs and carbon emissions. Its installation also extended the mine life by enabling access to previously unreachable ore.

In South Africa, Railveyor was first installed in 2007 at Harmony Gold's Phakisa mine in Welkom in the Free State. Transporting gold ore from the Phakisa shaft to the Nyala shaft before hoisting to surface, the system is fully automated apart from loading – providing a continuous, autonomous process. In this application, it navigates tight curves and transports high volumes of ore. Railveyor is represented and supported in that region by an established engineering firm, Deebar. 

More mines specify Railveyor 

Earlier this year, Railveyor was selected as the preferred haulage solution provider for Ivanhoe Electric's Santa Cruz Copper Project in Arizona. The system's fully electric haulage technology, flexibility, scalability and sustainable performance were critical factors for Santa Cruz, which is committed to low-carbon development strategies. 

Ivanhoe Electric has highlighted that the project's base case utilizes 70% renewable energy – resulting in low scope 1 and 2 carbon dioxide equivalent (CO2e). Compared to the industry average of 3.9 tonnes of CO2e per tonne of copper produced, emissions at Santa Cruz will be just 0.49 tonnes. The project is expected to be an industry-leading example of responsibly produced copper in the US throughout its anticipated 20-year mine life.

Railveyor was also selected as the preferred material haulage system in a pre-feasibility study for Burgundy Diamonds' Fox Project in Canada's Northwest Territories — presenting a strong case for Railveyor's value in reducing operational costs and enhancing a mine's long-term viability. Burgundy Diamonds' updated pre-feasibility study highlights the improved economics of Railveyor's lower operating costs and reduced infrastructure compared to traditional methods. Importantly, the system negates the need for an underground crusher and allows easy track extension as the mine deepens.

Enabling sustainable mining

Studies on Railveyor's performance in active mining operations demonstrated that the system reduced mine-wide emissions by up to 39%, when compared to diesel trucks. Railveyor also delivers on low operational costs, reducing operating expenditure by as much as 75% compared to truck haulage. The value delivered by Railveyor technology therefore helps mines to reduce both their cash costs and their emission levels.