Review of In-Pit Crushing and Conveying (IPCC) System and Its Case Study in Copper Industry
Review of In-Pit Crushing and Conveying (IPCC) System and Its Case Study in Copper Industry
Review of In-Pit Crushing and Conveying (IPCC) System and Its Case Study in Copper Industry
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Review of in-pit crushing and conveying (IPCC) system and its case study in
copper industry
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Abstract
The material transport system in an open pit mine significantly affects the capital and operating costs. All truck
haulage is the most common and is a reliable and flexible transport system. On the other hand, this system is very
expensive and can cost up to 50% of total mining costs. Its costs are continuously increasing due to the inflation of
the fuel, tire and labour expenditures. In-pit crushing and conveying (IPCC) is an alternative transport system which
requires a higher initial investment but gives substantial saving in operating cost. IPCC is the superior technology for
large open pit mines with high outputs. The main purpose of this review is to describe and compare IPCC system
types. Afterward, their advantage, disadvantage and reasons for applying have been demonstrated. Finally, their case
studies in copper industry have been accomplished.
1
PhD student of mineral processing, Tarbiat Modares University
2
MSc of mineral processing, process manager of Kani Faravar (Middle East Mineral Processing Eng. Co.)
3
BSc student of mining engineering, Sharood University of Technology
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1. Introduction
Currently the mining industry is increasing its focus on operational excellence and safety
performance toward zero-harm levels. Factors driving this increased focus include the need to
obtain greater efficiencies not only to address the rising capital costs for mining assets such as
equipment, fuel, tyres, and manpower, but their overall operation as well, and in-pit crushing and
conveying is an important part of this [1].
In 1956, the first mobile crusher was installed in a limestone quarry in Hover, West
Germany. The crusher enabled the quarry operator to take advantage of continuous belt conveyor
haulage and eliminated a problem of high-cost road construction and maintenance in wet soft
ground, with resultant cost savings. Since that time, the number of mobile in-pit crushing and
conveying operations has increased to over 1000 [2].
Semi-fixed systems may be in-pit but fixed within a pit stage [6]. These are mounted on a
steel platform, which reduces the need for a concrete foundation. Any planned relocation would
not be for less than 10 years [2].
Semi-mobile systems
This unit works close to the mine face but is moved less frequently than a mobile crusher. The
transport mechanism may be a permanent part of the crusher frame [2]. Semi-mobille systems are
suited to harder rocks and higher capacities (up to 10000tph) [6]. In this method, trucks are used
to transport material from the mine face to the in-pit crusher, often moving between levels. As
mining advances, the hauling distance to the crusher increase, eventually requiring the crusher
and conveyors to be relocated [7].
Relocatable systems
This term is used in Europe for crushers with temporary support foundations. The crusher plant is
moved in sections. In the United States, this term refers to units that can be moved on an highway
with a minimum amount of dismantling [2].
Movable systems
A movable crusher is centrally located in a mine near the same level as the mine’s working face.
It is relocated every 1 to 2 years, as required, to maintain the relationship between distance and
elevation from the face [2].
Type Specification
High Capacity
Typical Gyratory/Jaw Crusher
Fixed
Rarely Relocated
Commonly Associated With Transport Tunnel
High Capacity
Typical Gyratory/Jaw Crusher
Semi-Fixed
Relocated Every 3-5 Years
Commonly Associated With Transport Tunnel Or Wide Truck Ramp
Medium Capacity
Typical Twin Roll Crusher Or Sizer
Relocatable Relocated Every 6-18 Months
Multiple Crushing Station With Conveyor Ramp And Conveyor Distribution Point
Not Common In Deep Hard Rock Mine
Medium-Low Capacity
Typical Twin Roll Crusher Or Sizer
Relocated As Required To Follow Shovel
Movable
Commonly Feeds Onto Bench Conveyor Or Conveyor Bridge
Multiple Crushing Station With Conveyor Ramp And Conveyor Distribution Point
To Date, No Application In Large Scale, Hard Rock Mine
4. Conveyor systems
The size, weight, and physical characteristics of the material, transport rate, and horizontal and
vertical distances the material must be carried determine the type of conveying system to be used
to handle the material [2].
IPCC Conveying
Dedicated Ramp Conveyor Tunnel Conveyor on Haul Road
System
This open pit in Utah, U.S.A is currently under modernization to achieve a production of 70000
tonnes of ore per day using in-pit crushing and conveyor transport. The system consisits of a
semi-mobile 1.5 * 2.7 m (60-109 in) gyratory crusher and six belt conveyors.
The crusher weighs 1200 tonnes and is installed on concrete foundatios in a recess on a
bench at the conveyor tunnel portal elevation. It is fed by 154 tonne trucks from two sides. Total
height of the installation is approximately 30 m. Ore is crushed to a size of 250 mm at a
throughput rate of 9000 tonnes per hour. The feed hopper has a capacity if 600 m3. The discharge
belt is 3 m wide and 26 m long, with infinitely adjustable speed between zero and 0.5 m/s. the
plant is equipped with a hydraulic crane of 110 tonne lifting capacity and a hydraulic rock
breaker.
The mine uses six conveyors of a total length of about 8.5 km. The longest conveyor, which
is 6 km long, runs through a tunnel excavated in the pit wall to the surface. All conveyor belts are
1.8 m wide. Total Installed drive power is 12900 kw [14].
Fig. 9: In-pit crushing continuous haulage and spreading system at Escondida mine/chile [10].
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These are circular copper ore mines where the copper is covered by a very hard material. Before
installation of the conveyor the waste material was transported along the circular ramps: a very
expensive operation. ThyssenKrupp Fordertechnik has supplied in the last decades In-Pit
crushing continuous haulage and spreading systems for both of these mines, which have
drastically reduced the costs of operation.
ThyssenKrupp Fördertechnik’s In-Pit crushing continuous haulage and spreading systems
in Indonesia, China, Chile, Brazil, USA, Canada, South Africa, Zaire, Thailand, Australia,
Europe etc. prove that this technology is suitable for large open-pit mines and operates at high
performance levels with a very long service life under any climatic conditions [10].
10. Conclusion
While each mining situation needs to be independently evaluated, in-pit crushing and conveying
systems are increasingly cost effective in the following circumstances:
High capacity
Long mine life
Deeper pits
Longer haulage distance
High fuel cost
High labour cost
Remote controlled operation.
11. Refrence
[1] In-pit crushing and conveying-gathering momentum, 2011, International Mining.
[2] Frizzell, E.M. & Martin,T.W. 1990, In-pit crushing and conveying, Chapter 13.5.
[3] Scot Szalanski, P.E., 2009, Optimizing in-pit crusher conveyor performance, P&H Mining Equipment.
[4] Radlowski, J.K., 1988, In-pit crushing and conveying as an alternative to an all truck system in open pit mines,
The University of British Columbia.
[5] Koehler, F., 2010, In-pit crushing looms the way into Australia, Mining Magazine Congress.
[6] In-pit crushing and conveying (IPCC), 2010, Alan Cooper-Principal Consultant, Snowden Group.
[7] Bulk materials handling in mining, 2007, Sandvik Mining and Construction.
[18] Tutton D. & Streck, W., 2009, The application of mobile in-pit crushing and conveying in large, hard rock open
pit mines, Mining Magazine Congress.
[9] IPCC innovations, 2009, International Mining.
[10] Schroder, D.L., 2003, The use of in-pit crushing and conveying methods to significantly reduce transportation
costs by truck, Coaltrans Asia, Bali International Convention Centre.
[11] Oberrisser, H., 2009. Fully mobile crushers as part of total IPCC solutions, Sandvik Mining & Construction,
Mining Magazine Congress.
[12] Argall, J.G.O., 1976. Twin Buttes pit gets bigger, 550000 tones moved out of pit each day. World Mining, PP.
72-75.
[13] Anon., 1979. Pit crushers and conveyors move Sierrita ore and waste, PP. 279-28.
[14] Kaerst, D., 1987. Modern equipment for Kennecotts Bingham Canyon copper mine, Bulk Solid Handling, Vol.
7, No. 2.
[15] Engineered Solutions for Material Handling, 2010, Synergy Engineering Ltd.
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[16] Anon., 1984. Island copper: in-pit crusher and conveyor system under construction. Island Miner, Vol. 11, No.
1, pp. 1-2.
[17] Valley copper mines ltd., Vancouver, B.C., 1980. Valley copper project, Stage II Study, Vol. 1, Mining Plan.