Open pit mine aerial panorama — MCI Mining Technology mine planning
Senior Mine Planning Expert · MCI Mining Technology

Together We Shape
Technology

Through precise mine planning, we unlock the full potential of each operation — maximising efficiency, sustainability and value while paving the way for long-term customer success.

Each mine is unique – with tailored planning, we unlock site-specific potential and secure sustainable performance.

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3 yrs
IPCC Payback Period
$800M
NPC Reduction
50%
CO₂ Reduction
60%
Truck Fleet Reduction

Typical results from IPCC vs. conventional truck haulage projects

The Team

Expert Mine Planning at MCI Mining Technology

Decades of combined experience in open-pit mining, continuous mining systems, and bulk material handling — delivered through MCI Mining Technology's global engineering network.

30+ Years

"Through precise mine planning, we unlock the full potential of each operation — maximising efficiency, sustainability and value while paving the way for long-term customer success."

— Ulrich Mentges, Senior Mine Planning Engineer

Ulrich Mentges

Head of Mine Planning | Senior Mining Engineer — MCI Mining Technology

Ulrich Mentges brings over 30 years of mining engineering expertise, combining deep technical knowledge with strategic vision for open-pit mining, IPCC systems, and bulk material handling.

1993 Diploma in Mining Engineering — RWTH Aachen University
1995–98 Mining Engineer — SST Consulting GmbH
1998–22 Senior Mining Engineer — thyssenkrupp Mining (24 years)
2022–24 Senior Mining Engineer — FLSmidth
2026+ Head of Mine Planning — MCI Mining Technology
Mine Planning at MCI Mining Technology Download Mine Planning Overview (PDF)
9+ Years

"Each mine is unique – with tailored planning, we unlock site-specific potential and secure sustainable performance."

— Joel Bauer, Mine Planning Engineer

Joel Bauer

Mine Planning Engineer — MCI Mining Technology

Joel Bauer is an experienced mine planning engineer with an international academic background spanning RWTH Aachen, Aalto University Helsinki, and TU Delft — combining rigorous engineering methodology with practical site experience.

2017 M.Sc. Mineral Resources Engineering (European Mining Course) — RWTH Aachen · Aalto University · TU Delft
2017–20 Mining Engineer — Lhoist Germany
2020–21 Site Manager — RPBL
2021–24 Mine Planning Engineer — thyssenkrupp & FLSmidth
2026+ Mine Planning Engineer — MCI Mining Technology
63+
Years MCI
1871+
Projects
5
Global Offices
27+
Partners

Core Competencies

Areas of Expertise

Bucket wheel excavator — open pit mining technology

Open Pit Mining Technology

Expert knowledge of modern open-pit mining operations, equipment systems, and extraction methodologies for large-scale mineral deposits.

Mine planning feasibility study — aerial view of open pit

Mine Planning & Feasibility Studies

Comprehensive mine planning from conceptual to detailed design, including feasibility studies, 3D visualisation, and long-term mine scheduling.

In-pit crushing and conveying IPCC system

In-Pit Crushing & Conveying (IPCC)

Specialised expertise in IPCC systems as cost-effective alternatives to truck haulage. Semi-mobile to fully mobile crusher concepts — up to 50% CO₂ reduction.

Bulk material handling system — conveyor and spreader

Bulk Material Handling Systems

Design and optimisation of complete bulk material handling chains — bucket wheel excavators, conveyors, stackers and spreaders — tailored to site-specific conditions.

Financial modeling CAPEX OPEX mining risk analysis

Financial Modeling & Risk Analysis

Robust CAPEX/OPEX modeling, sensitivity analysis, and risk assessment. Cash-cost reductions of $0.18–1.00/t and NPC savings of up to $800M achieved.

Equipment selection and dimensioning — BWE system

Equipment Selection & Dimensioning

Strategic selection and precise dimensioning of mining equipment — BWEs, spreaders, conveyors, and crushing systems — matched to production targets and geology.

What We Offer

Services

Comprehensive mine planning consulting — from initial feasibility through to implementation support — delivered through MCI Mining Technology's global engineering network.

Application Engineering

Tailored solutions with flexible cost and performance options, guiding decisions from concept to execution. Early-stage collaboration to assess CAPEX, OPEX, flexibility, and scheduling impacts.

Mine Planning & Optimisation

Strategic support from feasibility studies to full system integration for efficient mining. Extensive database and simulations for optimised equipment and layout planning.

Feasibility Studies & Equipment Selection

Detailed evaluations, customised equipment designs, and 3D visualisations for bucket wheel excavators, spreaders, and complete IPCC systems.

Innovative Mining Systems

Optimised conveyor-based solutions reduce truck reliance by 20–60%, improving efficiency and cutting costs by $0.18–1.00/t. Up to $800M NPC reduction achievable.

Financial Modeling & Risk Analysis

Precise CAPEX/OPEX with sensitivity analysis for robust financial planning. Scenario modelling and risk frameworks enabling confident investment decisions at all project scales.

Mine Scheduling

Tailored schedules for continuous and discontinuous systems, ensuring alignment with mine design, production targets, and stripping ratios throughout the entire mine life.

Collaborative Development

Early-stage collaboration to assess CAPEX, OPEX, flexibility, and scheduling impacts — together with the client team.

Data-Driven Precision

Extensive database and simulations for optimised equipment and layout planning — grounded in decades of real project data.

End-to-End Support

Comprehensive support across the mining lifecycle, from feasibility to operations — one team, one mission.

Real Projects, Real Results

Case Studies

Selected projects demonstrating the measurable impact of expert mine planning and IPCC system implementation.

IPCC system for ore and waste — semi-mobile gyratory crushing station, 100 Mtpa
IPCC · Ore & Waste

IPCC for Ore & Waste — 100 Mtpa

Semi-mobile gyratory crushing stations combined with 60 km overland conveyor system. 9 pushbacks planned for 100 Mtpa ore and 180 Mtpa waste — delivering significant truck fleet reduction.

IPCC crushing station detail IPCC conveyor routing plan IPCC pit layout 3D visualisation
Waste IPCC prefeasibility study — OPEX and CO2 reduction
Pre-Feasibility · Waste IPCC

Waste IPCC Pre-Feasibility Study

OPEX and CO₂ reduction study for waste handling with IPCC at pit crest and mobile spreader concept. Delivered significant cash cost savings and sustainability improvements.

Waste IPCC at pit crest Mobile spreader concept Waste handling CAPEX OPEX analysis
Iron ore mine waste handling — overland conveying system, 4 routing solutions
Iron Ore · Waste Handling

Waste Handling — Iron Ore Mine

Overland conveying system study with 4 routing solutions evaluated. Full CAPEX/OPEX analysis enabling data-driven selection of the optimal haulage configuration.

Iron ore mine routing solutions comparison
Coal mine IPCC — coal seam model from drill hole data, conveyor integration
Coal Mining · IPCC

IPCC Integration — Coal Mine

Coal seam model developed from drill hole data, integrated with conveyor layout and financial modelling. Delivering reduced truck dependency and improved operational economics.

Coal mine financial modelling results

Continuous Mining Systems

BWE System Planning

Complete bucket wheel excavator system planning — from excavation scheduling to belt conveyor routing — using real geological data and proven simulation methodologies.

Excavation Planning
Volumes, duration, and multiple excavation lines — detailed schedules aligned with production targets.
Dumping Planning
Detailed schedules with parallel dumping lines — capacity balanced to match excavation throughput.
Belt Conveyor Routing
Long-distance and curved conveyor installations — optimised routing for minimal civil works and maximum reliability.
Bucket wheel excavator in operation — BWE system MCI Mining Technology BWE conveyor routing and belt installation BWE dumping planning — overland conveyor

Our Methodology

From Pit to Port

A structured project methodology with defined accuracy ranges ensures reliable results at every stage — from rough concept to bankable feasibility.

1
±25–40% · 4–16 weeks

Concept Study

Initial concept development, site data collection, rough equipment sizing and cost estimation.

2
±15–25% · 3–6 months

Pre-Feasibility Study

Detailed site analysis, equipment selection, preliminary mine layout design and CAPEX/OPEX modelling.

3
±5–15% · 4–9 months

Feasibility Study

Bankable feasibility with 3D visualisation, final equipment dimensioning, mine scheduling and risk analysis.

4
ECI · Early Contractor

Implementation Support

Early contractor involvement, procurement support, ongoing scheduling and operational performance monitoring.

MCI Mining Technology — global engineering excellence since 1962
MCI Mining Technology

Global Engineering Excellence Since 1962

Ulrich Mentges and Joel Bauer are part of the global MCI team — one of the leading engineering firms in mining and bulk material transport since 1962, with offices spanning four continents and 1871+ projects worldwide.

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Ulrich Mentges

Head of Mine Planning · MCI Mining Technology

[email protected] Mine Planning at MCI Mining Technology Download Mine Planning Overview (PDF)
MCI Mining Technology team — One Team One Mission Endless Spirit

Our Philosophy

ONE TEAM · ONE MISSION · ENDLESS SPIRIT