Big Roller™, energy efficient overland conveying with negative marginal cost of abatement energy efficient overland conveyor development

The Challenge 

Pilbara Iron Ore mining is the backbone of the Western Australian and Australian Economy with Forecast export earnings for 2022–23 of $113 billion. Big Roller™’s large diameter roller modular conveyor system has been designed specifically with this target market in mind.  

McKinsey’s Mine Decarbonisation Model indicates that approximately 41% of the energy used in a 25Million Tonne per annum iron ore mine is for Haulage and Conveying.  

Big Roller™ aims to displace the conventional designs for conveying (5% – electrical energy) with its energy efficient offering that provides a cheaper, faster installation and commercial ready alternative to Haulage electrification (31% currently diesel and 5% other energy source).  

This project aims to address the greenhouse gas emissions of Pilbara Iron Ore mining through more efficient ore conveyor systems. 

Proposed Solution 

Big Roller™ has hypothesized that a large diameter composite roller can be commercially produced to facilitate improved energy efficiency, through reduced Indentation Rolling Resistance and Rim Drag, whilst still having the mechanical strength and physical properties to perform under both existing and more arduous operating conditions (i.e. increased idler span and loads). 

Further, Big Roller™ has hypothesized that machined idler frames, combined with survey jigs and specialised installation equipment can facilitate semi-automation of construction processes.  

Proposed Benefits to WA 

This project is funded under the MRIWA Mining Technology, Equipment and Services (METS) Innovation Program. It demonstrates industry-led research which aims to develop new products, companies and markets for the Western Australian mining and minerals sector. 

Big Roller™’s patented design will help Australia, WA and mining companies reduce their carbon footprint by making ore transportation more energy efficient. 

Pilbara Iron Ore miners are adopting “hub and spoke” models to bring on remote orebodies, increasing utilisation of existing Ore Handling Plants. Big Roller™ estimate nearly 300kms of conveyors are required over 20 years, increasing to 400-500kms with haulage displacement.