Discover the benefits of complete crushing, grinding, drying and calcining plants

For some, they are Complete Mineral Beneficiation Plants. For others, they are simply crushing plants. The name chosen may vary, but the expansion of results is drawing the attention of mining companies to the adoption of complete plants.

One of the advantages of this type of project is the possibility of greater productivity. Lower costs, in areas such as maintenance, also drive the decision of business owners and managers.

However, the supplier must have expertise in the mining area, such as Máquinas Furlan. The possibility of customization in the development of equipment is another differential. The company also provides grinding plants, drying plants and calcination plants.

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What is a complete mining plant?

As the mineral processing process takes place under very adverse conditions, mining facilities need to be well dimensioned and adjusted to support variables such as the type of rock processed, abrasiveness, quality of the products generated, production capacity, among others.

In current times, flexibility is also a relevant factor, as even foreseeing the possibility of obtaining more than one final product must be considered.

There are also issues that go beyond, for example, the layout, to be adopted based on the existing scenario in the region of the deposit, and the results such as the granulometry and the arrangement of the products generated. Projects must also consider what the geographical feasibility will be.

Whether it is a product intended for agribusiness, aggregates for civil construction or for another purpose, the required quantity of ore processed in one stage cannot be greater than the capacity of the existing machine in the next step.

This balance is essential to avoid, for example, illusory capacity gains – in fact, in a short space of time, machines fed above the recommended level tend to present higher maintenance costs, or even breakdowns.

All of this will help define the characteristics of the equipment that will be needed.

What are the advantages of a complete plant in mining?

After collecting the data, industries need to define how they will acquire this equipment. Some of them prefer to go out into the field in search of suppliers that will meet the desired processes in a timely manner, assembling the plant with different brands.

However, there is an increasing number of mining companies that are preferring to have a complete plant. The advantages of this format begin with productivity.

When there is a single supplier, the final volume tends to be higher, since the needs study makes it possible to mitigate problems with mineral processing and size the plant within the real capacities of crushers, mills, screens and conveyors, among other equipment. Simulation software assists in decisions for complete solutions.

You already know, but it is worth reinforcing that mining has three fundamental stages that need to be aligned and remembered: crushing, grinding and screening. There are scenarios in which the products from the mentioned stages are raw materials for other production processes, such as the production of cement, ceramics, steel and then other processes such as grinding, drying, calcination are necessary. Furlan has in its product line equipment to meet these processes.

And there's more: adjusted operations tend to generate lower costs. Maintenance is easier when the manufacturer's recommendations are followed. The number of unscheduled shutdowns is reduced, avoiding losses in production volume and wasted hours worked by operators.

Energy efficiency is another point to be highlighted, being one of the main items in the cost spreadsheet of mining companies. Another component of this spreadsheet is the greater use of wear and replacement parts.

The human factor is also part of the list of benefits. Initially, choosing a single supplier allows mining company managers to spend their full time on their core business. In terms of operations, a complete plant provides greater safety for operators.

Supplier expertise is key

In this decision, the expertise of the plant supplier must be taken into account. Máquinas Furlan has one of the leading portfolios on the market, with more than 150 pieces of equipment available to equip the mines.

We tell the story of a mining company located in Mato Grosso do Sul that adopted the complete Furlan plant to produce aggregates and artificial sand. Projects of this size also include support in the initial phase of the plant's operation.

Another strong point is Furlan's culture of seeking customer success in mining through personalization. It has been operating with this focus for 61 years.

Thus, adjustments can be made to the equipment in order to achieve the best performance. For example: if necessary, the length of a conveyor belt can be extended to provide flexibility and gain storage capacity in the process of the product coming from a sieve.

This improvement always occurs in a structured manner, following studies and Regulatory Standards – including NR-10 and NR-12. The practice provides productivity without losing operational safety.

A team of mining experts supports these decisions. The New Products and Services Department, DNPSA, brings together representatives from various areas of Furlan to study the best alternative for the client.

The analysis includes the type of alloy to be used in parts such as hammers, grates, mantles and linings. Choosing a single brand with experience in mining speeds up scheduled maintenance.

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