Doe Run has operated for more than 150 years as a responsible mining and metal production company and in 2018/2019, its Casteel lead/zinc/copper mine in southeast Missouri became the first mine in the United States, and only the second commercial operation in the world, to install the Rail-Veyor continuous rail hauling system. The Rail-Veyor system operates like an underground electric light rail system. The automated system currently transports ore over three miles underground and can be expanded further if necessary.
“This technology has the potential to revolutionise underground mining,” said Steve Dismuke, Technical Services superintendent at Buick Mill, and project manager for Rail-Veyor. “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.”
Previously, a hoist system at Casteel mine brought ore to the surface, where it was trucked by public road to be processed at Buick mill. The hoist system operated at a maximum capacity of 3,600 tons of ore each day, which gave the mine no room to increase production. Now that it is possible to load rail cars on a continuous loop, Casteel can transport 800 tons more ore to the mill each day, and still have the hoist system as a backup option.
“One of the added benefits of Rail-Veyor is that it will reduce traffic on community roads,” said Dismuke. “The train will replace 200 one-way haul truck trips each day.” Each Rail-Veyor train eliminates ten truckloads per hour. Originally, Casteel mine was looking at using existing railroad track on surface for the Rail-Veyor to transport the lead/zinc/copper ore to Buick mill but after further analysis it was found that the system could be installed in existing underground drifts taking it all the way to the processing operation.
Rail-Veyor requires only one operator to start and monitor the system. The operator uses a series of cameras to observe the rail system in real time from any location with an internet connection. This enables the operator to quickly identify potential issues or maintenance requirements. Employees who previously worked on the loaders and hoist system now operate Rail-Veyor or hold other underground jobs, giving them new opportunities and helping maximise production. Rail-Veyor is expected to provide strong savings year over year.
