Optimizing oversize material handling for sustainable operations: A case study at LKAB Norge AS

Abstract

This thesis examines methods to improve the handling of oversized iron ore at LKAB Norge AS, aiming to increase efficiency, reduce environmental impact, and support sustainable operations. Oversized material, fragments larger than 40 mm, presents challenges in the current system, including delays, manual transport, increased emissions, and additional wear on equipment. Regulations also require indoor processing, which limits the use of mobile crushers.

A literature review was conducted to understand current technologies related to screening, crushing, and material handling. The study focused on modern solutions such as high-pressure grinding rolls (HPGR), hybrid crushers, and automated control systems. Several technologies were compared based on energy use, flexibility, installation requirements, and long-term costs.

Based on this analysis, a new hybrid crushing system is proposed for a location called NK40. This system combines HPGR with an initial impact-crushing stage and is designed for indoor operation. It includes dust control, energy-saving components, and monitoring tools to ensure efficient and reliable performance.

The results indicate that the system can reduce energy consumption by up to 52,000 kWh per year, compared to a traditional crusher, decrease operational costs by 28%, and increase annual revenue from USD 1.6 million to USD 4.44 million by processing oversized material into higher-value products. In addition to improved performance, the system supports LKAB's environmental and strategic objectives.

The thesis concludes that this solution provides a realistic and cost-effective approach to improving oversized material handling at LKAB Norge AS.