The Brokk Vacuum Excavation System: An innovative Solution in Mining Operations

Chile, as the world’s leading copper producer, relies heavily on conveyor systems in its vast open-pit mines, which are essential for transporting materials such as ore between extraction and processing plants.

One of the most notable sites in Chile is the El Abra mine, operated by Freeport McMoRan, home to the longest and most robust conveyor belt system in the world, stretching over an impressive 20 kilometers.

Challenges in Maintaining Conveyor Systems

Maintaining these massive conveyors in peak condition is crucial to avoiding costly complications, including material build-up and the risk of fires caused by friction with the rollers. These issues not only threaten safety but can also force partial or complete production shutdowns, resulting in staggering costs of up to hundreds of thousands of dollars per hour.

Traditional Methods: Inefficiencies and Hazards

Traditionally, cleaning under these conveyors has been a labor-intensive and hazardous task, requiring workers with shovels and wheelbarrows or using combustion-powered carriers. This approach is not only inefficient and expensive but can only be carried out during scheduled downtimes—typically three to four times a year—or in response to unexpected malfunctions.

The Brokk Vacuum Excavation System: A Game-Changing Solution

In Peru, our distributor Recomaq introduced an innovative solution for cleaning conveyor belts by offering the Brokk Vacuum Excavation System with the BROKK 110 to Southern Peru Copper Corporation, demonstrating its effectiveness and potential for wider use in major mining operations.

Recognizing the critical need for an effective solution, our distributor in Chile, Socomaq, seized the opportunity during visits to mining sites operated by industry giants like BHP, Freeport McMoRan, Codelco, and Anglo American. After conducting a thorough analysis and on-site demonstrations, Socomaq introduced a groundbreaking innovation to these clients: the Brokk Vacuum Excavation System, paired with the Brokk 110. The results speak for themselves!

Enhanced Safety for Operators and Infrastructure

One of the most significant advantages is the enhanced safety for both operators and infrastructure. The radio-controlled system allows precise cleaning under moving conveyors, ensuring operator safety and protecting infrastructure. According to Domingo Gonzalez, Socomaq’s Mining Division Manager, the Brokk Vacuum Excavation System supports decarbonization efforts by reducing silica exposure and eliminating musculoskeletal strain for operators—key objectives for Chilean mining companies.

As a result, working conditions have improved dramatically, as observed by contractors at BHP. Keeping operators healthy and safe remains a top priority, especially in an industry where it’s notoriously difficult to find committed manpower.

Boosting Operational Efficiency and Reducing Costs

In addition to enhanced safety, the Brokk Vacuum Excavation System has dramatically improved operational efficiency, significantly reducing the risk of costly stoppages by 80%. These uninterrupted operations can save between $10,000 and $200,000 per hour, depending on the size of the mine, according to metrics shared by a BHP contractor. The system’s design also ensures maximum efficiency, maintaining the suction duct’s diameter to optimize vacuum truck performance.

Cost reductions extend beyond operational uptime. The Brokk Vacuum Excavation System requires just two operators, compared to the eight workers previously needed for manual cleaning, as highlighted by Codelco.

The response has been very positive, operators realize that they can learn to handle the Brokk well, making work easier, faster, and safer, added Gonzales.

 

‘’It doesn’t pose a threat to their jobs; on the contrary, it allows them to be more competitive when it comes to renewing their company’s contract with the mining company.’’

Additionally, maintenance costs have been reduced by 70%, as the electric motors require less frequent and simpler maintenance compared to combustion engines. This, combined with the fact that Brokk machines have more than triple the lifespan of their combustion-powered counterparts, significantly lowers long-term expenses.

Sustainability: A Zero-Emissions Future for Mining

Sustainability is another crucial benefit. The system is electrically powered, which not only eliminates downtime for battery recharging or filter cleaning but also completely removes emissions from the equation. This is particularly important in underground mining, where air quality is a critical concern, and helps mining companies meet their carbon footprint reduction targets.

Transforming the Future of Mining Operations

We’re also rewriting the belt cleaning methodology because we’ve achieved results in these cleaning performances never seen before, said Gonzales.

 

The Brokk Vacuum Excavation System is revolutionizing mining operations in Chile and beyond by delivering unparalleled safety, efficiency, and sustainability, setting new industry standards.