Material Handling Case Studies

Case Studies

Prospecting for Profitability With Railveyor

INTRODUCTION

Railveyor is an advanced material haulage solution for both mining and industrial applications – a revolutionary concept now proving its value in the field.

When Railveyor began commercial development over a decade ago, we were confident that the system would deliver on the promise of more energy efficient and profitable material handling for the mining industry. In ensuing years, Railveyor has been successfully deployed in mining operations and industrial applications across the world.

Initially, some customers are skeptical about the dramatic, innovative Railveyor promise. But, through rigorous due diligence and customized application planning, the engineering puts their mind at ease. Throughout the process of evaluation, installation and operation, the Railveyor team partners with our customers to address the dynamics of their unique problems and opportunities.

As tonnage rolls in, CAPEX and OPEX are calculated, ESG metrics are tabulated, and boards and shareholders are briefed, Railveyor’s value is revealed in real time, time and again. Yesterday’s concept is today’s reality – and we have the numbers and stories to prove it.

Case Study

Agnico Eagle

2018: Val-d’Or, QC (Canada)
3 km long
600 tons/h – Underground 17.5% Grade System

Mine Saved:
Extended mine
life past 2025

Eliminates:
28,000 truck
trips/year

Impact

Extended the life of the mine by increasing profitability through minimized dependency on truck haulage, reduced ventilation costs and optimized development potential. Railveyor’s automation made up for productivity losses incurred during mandatory COVID-related shutdowns.

Agnico Eagle’s Goldex Mine, located in Val-d’Or, Quebec is a relatively low-grade gold orebody beset with geotechnical challenges. The “Deep 1” zone was discovered in 2007 but initially written off as unprofitable to mine due to issues around rock stability and ventilation costs associated with truck haulage. The entire Goldex mine was slated to be closed by 2018 until the Railveyor system rejuvenated the successful mining of Deep 1.

+18% production increase, setting an all-time record at Goldex mine
-14% cost per ounce saved on gold produced
$8M saved in one year due to reduced costs
+7 years to the lifespan of the mine
Q4 2020: 5 million tons hauled since commissioning

“Innovation is like Exploration. If you don’t drill, you won’t find anything. If you don’t invest in technology and ideas, and invest in your people who are bringing those ideas forward, then you aren’t going to improve your business … people know if they come forward with a good idea, we will find a way to fund it. That’s the way we’ve run the business for many, many years. When we get ideas at certain sites to dramatically change the cost structure or improve the efficiencies based on introducing a new technology then we listen as much as we listen when we’ve got a good drill result at a deposit. Good example is the Railveyor at Goldex. Old technology applied in an innovative way which lowers the cost as we go deeper.”

— Sean Boyd CEO, Agnico Eagle Mines Ltd

Railveyor was able to make a lower-grade ore profitable to mine through reduced ventilation costs with all electric motors. Combined with energy sourced through hydroelectric power, carbon emissions are potentially lowered as well.

Goldex Railveyor Video

Case Study

Doe Run

2019: Near Boss, Missouri (USA)
Lead / Zinc / Copper
3.4 miles long
174 tons/h — Underground System

2 Trains (400m each) – 25 Drive Stations
Commissioned Within 10 Months

Slashed OPEX by:
92%

Increased Daily Ore Deliveries by:
22%

Impact

We engineered a replacement for over-the-road truck haulage in partnership with the Doe Run Company, saving 92% on the customer’s OPEX costs. Because of the minimal drift clearance required by the system, we proposed a completely underground route using existing tunnels – an unexpected solution that removed traffic from surface roads.

The Doe Run Company was looking to reduce their over-the-road truck haulage at the Casteel Mine in Missouri. This need was especially critical because the truck routes went through the Mark Twain National Forest, causing some level of noise and dust in the natural environment and near communities. The existing hoist system also placed a significant bottleneck on the development potential of the mine.

Reduced OPEX costs by 92%
+800 tons of ore delivered to mill daily (previously 3600 tons/day)
Eliminates 200 one way truck trips daily
Over 98% system availability since commissioning
Employees were retrained and retained

“Railveyor has the potential to revolutionize underground mining. As an early adopter of the system, this can provide us with efficiencies that other companies don’t have. We expect other companies will want to come and see our rail in operation.”

— Steve Dismuke, Technical Services Superintendent at Buick Mill

Keeping the material transport system underground allowed Doe Run to eliminate 200 truck trips per day from traveling through the beautiful Mark Twain National Forest, aligning with the company’s overarching Sustainability strategy.

Safety signals at key points along the Railveyor Track keep personnel aware of oncoming Trains when they may be working nearby.

Case Study

Maroil

2020: South America
Petroleum Coke from Refinery
4.2 km long — 19 Drive Stations
700 tons/hr — Surface System

Custom-Designed Deep Trough Train

Improved Safety
and Environmental
Outcomes

Remotely
Commissioned
During Global
Pandemic

Impact

Railveyor delivered a quieter, safer solution to deliver petroleum coke from a refinery to a port terminal, reducing risk of fire and noise pollution. The end point was a radial telescopic conveyor on a pier, so the Railveyor team designed a custom building to house the discharge loop. Despite being installed during the global travel shutdown during the COVID-19 pandemic, the system was remotely commissioned by our team in Canada.

The customer needed an energy efficient solution which could operate quietly and cleanly on the surface near a community. Conveyors transporting petroleum byproducts are at a heightened risk of fire. The installation of the system commenced immediately prior to the COVID-19 global pandemic.

“When Covid hit, Railveyor was confronted with the challenge of how to commission a system without a Railveyor expert on site. Using repurposed video conferencing software, we had successfully controlled our test site from an office 20km away, and we thought, ‘Why not 5000km away?’ Using a remote connection, we viewed key variables of the customer’s system, modified the program as needed, and assisted in customer maintenance needs. So despite a global shutdown of travel, across different time zones and through several languages spoken, Railveyor successfully completed the commissioning of our material haulage system.”

— David Niemeyer, Automation Technologist, Railveyor

Railveyor’s minimal clearance requirements, low noise level and reduced fire risk made it the perfect solution to transit semi-urban areas.

Through the global shutdown, the Railveyor TrulyAutonomous system was able to be commissioned remotely from our offices in North America, keeping the project on schedule.

Case Study

Vale Copper Cliff Orebody 114

2012: Sudbury, Ontario (Canada)
Copper Ore
2,500 feet long
Maximum 15% Gradient – 53 Cars

Allowed Rapid
Development

Proved Commercial
Feasibility

Impact

Railveyor doubled Vale’s typical development rate (122m/wk), achieving the company’s ambitious test target while reaching an orebody faster by decreasing requisite drift size. Railveyor’s exceptional performance enabled a development rate of 143 meters advanced per week. This success caught the attention of the world and inspired additional commercial applications.

Underground advance rates in Canada have declined, now barely reaching 150 feet per week. As an industry leader in mining, Vale was keen to put Railveyor’s technology to the test at their Copper Cliff Mine at Ore Body 114. Previously shut down due to the global financial crisis, this near surface deposit was the perfect place to see how Railveyor might improve their development rate.

“The thing that impressed me most with Railveyor was how quickly it was constructed. I think the real benefit is your ability to get into production and development much quicker than with some other historical systems.”

Kate McLaughlin, P.Eng., M.Sc., Vale, Manager Technical Systems Development Canada

Railveyor was proud to partner with industry leader Vale in testing the system’s improvements towards development rates.

Railveyor was able to easily handle a 15% grade and our minimal requirements for drift clearance exceeded Vale’s targeted development rate.

Contact Information

Railveyor is an advanced material haulage solution for both mining and industrial applications – a revolutionary concept now proving its value in the field.

Agnico Eagle

Impact

Doe Run

Impact

Maroil

Impact

Vale Copper Cliff Orebody 114

Impact

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