FAST TRACK SOLUTION CRUSHING PLANT: PROCESS INNOVATION, CIRCULARITY & RECOVERY *J.O. Vela1, E. Nunes2 1Manager Technology, Metso, Perú, (*Presenting author: oswaldo.vela@metso.com) 2Manager, Product & Sales Support, Metso, Brasil ABSTRACT This research analyzes the operational optimization of the S11D Project in Brazil to mitigate failures in transport systems through modular engineering. The study addresses unscheduled shutdowns due to tears in the 9.5 km conveyor belt, caused by excessive granulometry of 430 mm and lamellar ore geometry. The solution consisted of a secondary crushing stage featuring Hydrocone equipment and screens mounted on skid-type bases. This approach eliminated the need for permanent civil infrastructure by complying with the AISC 360-16 standard, utilizing the Allowable strength design method. The results show a 28% reduction in the assembly schedule and a capacity of 2,200 t/h reached in fifteen days. The 150 mm product with rounded morphology eliminated transport incidents, ratifying modular efficiency for operational continuity and asset flexibility in large-scale mining. KEYWORDS Modularization, Skid-type bases, Secondary crushing, Operational availability 1. INTRODUCTION The S11D Project utilizes the Truckless system, integrating excavators and mobile crushers to replace truck haulage. Originally, primary jaw crushing discharged ore up to 430 mm directly onto a 9.5 km long-distance conveyor belt (Figure 1). This configuration caused recurrent belt tears due to the granulometry, the lamellar morphology of the ore, and high impact energy. The resulting unscheduled shutdowns increased operating costs and reduced system availability due to prolonged repair times.
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