In Pit Crushing and

Conveying System (IPCC)

Muhammad Badar Hayat
Mining Engineering
4/30/2014

Outline
What is IPCC?
IPCC Operation
History
Usage
Types of IPCC systems
Cost comparison
Advantages
Disadvantages
Recommendations
conclusion

What is IPCC?

(2014) matt-gerten.pdf.
http://gcaa.org/ppt/matt-gerten.pdf

IPCC and Convetional truck haulage

system

Norgate, T. and Haque, N. (2013) The greenhouse gas impact of

IPCC and ore-sorting technologies. Minerals Engineering 42, 13-21

Components of IPCC System

IPCC Operation
https://www.youtube.com/watch?v=doNcV
s-APvY

History

First introduced in the mid-1950s by a limestone quarry in Germany

First large-capacity IPCC system was installed in 1970
In1980s the IPCC concept came to the forefront due to

Increase in oil prices due to Arab embargo

Higher demand
US bureau of mines

Increasing since 1980

Koehler, F. (2003) In-Pit Crushing System the Future Mining Option. (1 edn), pp. 371-376
(2014) SUR_AppHandBook_IPCC.pdf. http://w.kitpackers.com/files/en/SUR_AppHandBook_IPCC.pdf

Usage

The IPCC system is being used successfully in large gold, copper ,

iron and coal open cut and open pit mines

Norgate, T. and Haque, N. (2013) The greenhouse gas impact of IPCC and oresorting technologies. Minerals Engineering 42, 13-21

Types of IPCC Systems

Stationary crushing system

Mobile crushing system

Semi-mobile crushing system

Koehler, F. (2003) In-Pit Crushing System the Future Mining Option. (1 edn), pp. 371-376
IndependentMiningConsultants (2014) IN-PIT CRUSHING AND CONVEYING - . Continually moving or
multiple http://www.infomine.com/library/publications/docs/IndependentMiningConsultants1985.pdf
Terezopoulos, N. (1988) Continuous haulage and in-pit crushing in surface mining. Mining
Science and Technology 7, 253-263

Cost comparison IPCC and Dump truck

system

Zimmermann, E. and Kruse, W. Mobile crushing and conveying in quarries-a

chance for better and cheaper production!

Cost comparison IPCC and Dump truck

system

In another granite quarry in Canada, the reorganization of the quarry from

the dump truck haulage system to IPCC system resulted in a reduction of
50% operating cost

Zimmermann, E. and Kruse, W. Mobile crushing and conveying in quarries-a

chance for better and cheaper production!

Advantages

Operating costs per ton of material conveyed, particularly on long

uphill climbs, are cheaper.
Capital and investment cost related with the trucks is eliminated
Pit life is extended
Haul roads and their maintenance is not required
Labor costs associated with trucks are eliminated
Weather has least effect on the operation
Safety is enhanced by elimination of trucks

IndependentMiningConsultants (2014) IN-PIT CRUSHING AND CONVEYING - . Continually moving or

multiple http://www.infomine.com/library/publications/docs/IndependentMiningConsultants1985.pdf

Advantages

The power used for the system is electricity which is more

economically stable than diesel fuel used in trucks
More environment friendly due to reduction of greenhouse gas
emissions
The equipment involved has higher resale value
The equipment has longer lifetime up to 50 to 60 years
Lower investment costs keeping in view the overall mine life cycle
Lower dust and noise pollution.

Zimmermann, E. and Kruse, W. Mobile crushing and conveying in quarries-a

chance for better and cheaper production!
(2014) IPCC, (In-Pit Crushing and Conveying) is the future - as is Metso hard rock mining
solutions.
http://www.metso.com/miningandconstruction/mm_proj.nsf/WebWID/WTB-130425-2256F-CBE6E?
OpenDocument#.U2BsIlfiiuI

Disadvantages

It has a high initial capital cost

Less flexible to various mine plans or mining condition changes
A greater effort is required in mining
It is harder to integrate into a stripping system.

(2014) SUR_AppHandBook_IPCC.pdf.
http://w.kitpackers.com/files/en/SUR_AppHandBook_IPCC.pdf

Recommendations

Mine life should be more than 10 years.

The haul distances should be long.
Large and steady tonnages of material are being moved.
Electricity price should be considerably less than the diesel price in
the area.
Where lower operating costs are required.

(2014) New IPCC ideas.

http://www.infomine.com/library/publications/docs/InternationalMining/Chadwick2010w
.pdf#page=1&zoom=auto,4,846

Recommendations

In case if in pit crushing is not required and only the long truck
haulage route has to be replaced, skip haulage system can be
adopted.

Wolpers, F. (2013) Cost-efficient Transport for Open-pit Mines. Engineering & Mining
Journal (00958948) 214, 48-52

Conclusion

It seems that in near future the IPCC system will replace the
conventional dump truck system in large mines due to its low
operating, labor and fuel cost.
Moreover the environment friendly nature of this IPCC system
makes it a strong candidate as a future haulage system.
In small mines the dump truck system however may be more
feasible.

References
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(2014) matt-gerten.pdf. http://gcaa.org/ppt/matt-gerten.pdf .

Norgate, T. and Haque, N. (2013) The greenhouse gas impact of IPCC and ore-sorting technologies.
Minerals Engineering 42, 13-21.
Koehler, F. (2003) In-Pit Crushing System the Future Mining Option. (1 edn), pp. 371-376
(2014) SUR_AppHandBook_IPCC.pdf. http://w.kitpackers.com/files/en/SUR_AppHandBook_IPCC.pdf
Norgate, T. and Haque, N. (2013) The greenhouse gas impact of IPCC and ore-sorting technologies.
Minerals Engineering 42, 13-21
IndependentMiningConsultants (2014) IN-PIT CRUSHING AND CONVEYING - . Continually moving or
multiple http://www.infomine.com/library/publications/docs/IndependentMiningConsultants1985.pdf
Terezopoulos, N. (1988) Continuous haulage and in-pit crushing in surface mining. Mining Science and
Technology 7, 253-263
Zimmermann, E. and Kruse, W. Mobile crushing and conveying in quarries-a chance for better and
cheaper production!
(2014) IPCC, (In-Pit Crushing and Conveying) is the future - as is Metso hard rock mining solutions.
http://www.metso.com/miningandconstruction/mm_proj.nsf/WebWID/WTB-130425-2256F-CBE6E?OpenD
ocument#.U2BsIlfiiuI
(2014) New IPCC ideas.
http://www.infomine.com/library/publications/docs/InternationalMining/Chadwick2010w.pdf#page=1&zo
om=auto,4,846
Wolpers, F. (2013) Cost-efficient Transport for Open-pit Mines. Engineering & Mining Journal
(00958948) 214, 48-52