FLS semi-mobile crushing at Vale’s S11D: IPCC layout notes for mine planners
Reviewed by Tom Sullivan

First reported on International Mining – News
30 Second Briefing
FLSmidth has installed a large semi-mobile crushing station with sizer technology at Vale’s S11D Serra Sul iron ore operation in Brazil, with the first 26 m-high module commissioned in Area 5 to open new mining blocks. The semi-mobile design allows relocation as the pit advances, reducing truck haul distances to the conveyor network and supporting S11D’s high-throughput, low-strip-ratio mine plan. For mine planners and process engineers, the setup signals continued shift towards in-pit crushing and conveying (IPCC)-style layouts at large-scale iron ore operations.
Technical Brief
- First semi-mobile station module stands 26 m high, indicating multi-level structural and access requirements.
- Structural steelwork and foundations must accommodate relocation loads as well as normal operating vibration and impact.
- Semi-mobile concept reduces need for permanent retaining structures and deep foundations compared with fixed plants.
Our Take
Vale’s S11D iron ore complex in Brazil already features heavily in our Mining coverage as a margin-critical asset, so deploying a 26 m-high semi-mobile crushing module here signals that FLSmidth’s solution is being proven at one of the world’s benchmark bulk operations rather than at a peripheral site.
With iron ore again prominent in recent valuation pieces on diversified majors, any throughput or cost gains from the new crushing station at S11D are likely to have an outsized impact on Vale’s earnings sensitivity compared with smaller Brazilian operations.
Fluor’s 2025 acquisition of FLSmidth’s Overland Conveyor Products Group suggests that future expansions or replications of this semi-mobile crushing concept at Vale sites could see a more fragmented supply chain, with crushing and conveying packages no longer coming from a single OEM group.
Prepared by collating external sources, AI-assisted tools, and Geomechanics.io’s proprietary mining database, then reviewed for technical accuracy & edited by our geotechnical team.
Related Articles
Related Industries & Products
Mining
Geotechnical software solutions for mining operations including CMRR analysis, hydrogeological testing, and data management.
Construction
Quality control software for construction companies with material testing, batch tracking, and compliance management.
CMRR-io
Streamline coal mine roof stability assessments with our cloud-based CMRR software featuring automated calculations, multi-scenario analysis, and collaborative workflows.
HYDROGEO-io
Comprehensive hydrogeological testing platform for managing, analysing, and reporting on packer tests, lugeon values, and hydraulic conductivity assessments.
GEODB-io
Centralised geotechnical data management solution for storing, accessing, and analysing all your site investigation and material testing data.