In pit crusher conveyour system

IN PIT CRUSHER CONVEYOR SYSTEM
A CASE STUDY (RG OCP-II MINE)
MAIN PROJECT REPORT SUBMITTED IN PARTIAL
FULLFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE OF
Bachelor of Technology
Mining Engineering
By
BHUKYA KOTESH - 13671A2504
BOMMA PRASHANTH REDDY - 13671A2505
KATHROJU KAMALAKAR - 13671A2518
DEPARTMENT OF MINING ENGINEERING
JB Institute of Engineering and Technology
(UGC Autonomous & Affiliated to JNTUH)
Hyderabad-500075
2013-2017

J.B. Institute of Engineering and Technology
(UGC Autonomous)
Department of Mining Engineering
CERTIFICATE
This is to certify that the project entitled “IN PIT CRUSHER
CONVEYOR SYSTEM - A CASE STUDY (RG OCP-II MINE)” being
submitted to the department of Mining Engineering, J.B. Institute of Engineering
and Technology in accordance with JNTUH regulations as a part of IV B.Tech
II Semester for successful completion of Bachelor of technology degree in
Mining Engineering and this project work carried out under the guidance of Sri.
GALAB KHAN Associate Professor during the academic year 2016-17.
Project Internal Guide Head of Mining Engineering
GALAB KHAN Ch. VEERA REDDY
Associate Professor Professor and HOD
External Examiner

ACKNOWLEDGEMENT
First and foremost, we express our sincere thanks to our college Principal Sri. Dr. P.V.S.
SRINIVAS his kind co-operation. We express our sincere gratitude and indebtedness to Sri.
CH. VEERA REDDY, HOD of Mining department and Sri. GALAB KHAN PATHAN,
Associate Professor in Department of Mining Engineering for allowing us to carry on the
present topic “IN PIT CRUSHER CONVEYOR SYSTEM - A CASE STUDY (RG OCP-II)”
and later on for his inspiring guidance and valuable suggestions throughout this project work.
We are very much thankful to them for their valuable guidance in understanding of this project.
We express our heartiest thanks to Ramagundam area SCCL Mining staff members
who have given their valuable suggestions for the completion of this project work.

IN PIT CRUSHER CONVEYOR
SYSTEM
A CASE STUDY (RG OCP II)

CONTENTS
PART 1
Sl.no: Particulars Page no:
CHAPTER 1
1.1 Abstract 1
1.2 Introduction 2
1.3 Definition of in-pit crushing and conveying (IPCC) system 2
1.4 In pit crusher conveyor system 2
1.5 Types of in-pit crushing systems 4
1.6 Fixed or semi-fixed systems 4
1.7 Semi-mobile systems 4
1.8 Fully mobile systems 5
1.9 Comparison of in-pit crushing system types 6
CHAPTER 2
2.1 Working of in pit crusher conveyor systems 8
2.2 Sequence of Operation 9

2.3 Different parts of IPCC system 9
2.4 The main components of double roll semi-mobile crushing plants 10
2.5 Technical data of semi mobile crusher 11
CHAPTER 3
3.1 Maintenance of crushing plant 13
3.2 Propermaintenance 14
CHAPTER 4
4.1 Crusher 16
4.2 Technical Data of Crusher 17
4.3 Types of crushers 19
4.4 Crusher working layout 20
CHAPTER 5
5.1 Conveyor 21
5.2 size of the material for the belt conveying 23

5.3 Technical data of conveyors 23
CHAPTER 6
6.1 Conveyor Distribution point(CDP) 26
CHAPTER 7
7.1 Spreader 27
7.2 Technical data of spreader 28
CHAPTER 8
8.1 Costper Cu.m for truck dumping 30
8.2 Costper Cu.m against system dumping 30
CHAPTER 9
9.1 The Advantages of ICC System are 32
9.2 Disadvantages of ICC System 32

PART II
CHAPTER 10
10.1 Location Plan of RG OC-II 34
10.2 Brief Description 35
10.3 Salient Features of Extension Project 36
10.4General arrangement of crusher conveyor technology at RG.OC-IIproject37
10.5 Semi Mobile Double Roll Crushing Plant at RG.OC-IIProject 38
10.6 Applicability of ICC system in SCCL 39
10.7 Conclusion 40
10.8 Reference 41

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PART I
CHAPTER 1
1.1. 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, the case study in a coal mine have been accomplished.

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1.2. 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 efficiency 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. 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.
1.3. DEFINITION OF IN-PIT CRUSHING AND CONVEYING (IPCC)
SYSTEM:
A continuous processing system that includes the shovel, crusher, spreader and all
appropriate conveyors that reduces rock of mine (ROM) to a conveyable size. In fact, IPCC is
the use of fully mobile, semi-mobile or fixed in-pit crushers coupled with conveyors and
spreaders (for waste) or stackers (for ore) to remove material from an open-pit mine. Following
figures make a good view of In-Pit crushing system.
1.4. IN PIT CRUSHER CONVEYOR SYSTEM:
► IPCC SYSTEM means In pit crusher conveyor system.
► IPCC system is also called as SEMI MOBILE CRUSHER.
► IPCC system crushing of overburden and coal inside the quarry and transporting them by
belt conveyors.
► The proposed Crusher / Sizers shall be of Semi Mobile type since they are required to be
shifted in the Opencast Mine periodically as per progress of the Mine.
► The Crushers / Sizers shall have a life of around 25 years.
► Annual operating hours of the equipment shall be 4500 to 5000 hours.375-417 hours per
month and 12.5-14 hours per day.

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► Total weight of the Equipment 640 tonnes.
► Cost of the Equipment (in 1994) is 16.50 crores
► In-pit crushing and conveying is an alternative system for transport in open pit mines.
Depending on individual parameters, it can achieve full or partial replacement of trucks for
material transport within and out of a mine. If a mine provides two conveyors, both ore and
waste are conveyed out of the pit. By this way, the truck transport on long uphill distance is
eliminated. When the mine supplies only one conveyor, it conveys ore and waste on different
shifts, or all the waste is transported by trucks to the surface.
►The in-pit crusher is moved down every one or two years, to keep the truck haulage to a
minimum. The relocation takes 2-3 days. For short moving times the processing plant can be
fed from a stockpile. In longer stoppages, usually in European operations, the move coincides
with a general mine holiday period.
► The crusher is located next to an embankment, so that trucks are able to dump the material
directly from the embankment into the hopper/feeder above the crusher. Under an alternative
arrangement, the crusher is located closer to the center and has a separate feeder with the feeder
tail-end located in the recess in the pit floor. The trucks dump the material from the pit floor
into the hopper on the feeder. Belt conveyors can be one of the most efficient means of
transporting material out of the pit.
►Currently the mining industry is increasing its focus on operational excellence and safety
and conveying is an important part of this.
► 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.

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1.5. TYPES OF IN-PIT CRUSHING SYSTEMS
1.6. Fixed or semi-fixed systems.
1.7. Semi-mobile systems.
1.8. Fully mobile systems.
1.6. FIXED OR SEMI-FIXED SYSTEMS
Fixed systems are typically ex-pit and are designed to reduce haulage distance to the waste
dump Semi-fixed systems may be in-pit but fixed within a pit stage (as shown fig 1 below).
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.
Fig. 1 Fixed or Semi-fixed Systems
1.7. 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. Semi-mobile systems

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are suited to harder rocks and higher capacities (up to 10000tph). In this method, trucks are
used to transport material from the mine face to the in-pit crusher, often moving between
levels(as shown in fig 2 below). As mining advances, the hauling distance to the crusher
increase, eventually requiring the crusher and conveyors to be relocated.
Fig. 2 Semi-Mobile Systems
1.8. FULLY MOBILE SYSTEMS
Fully mobile systems are based on sizes and limited to softer rocks and the shovel capacity
( ̴ 5000 tph). These type of crushers work at the mine face, are directly fed by an excavator,
and move in unison with the excavator on them own transport mechanism as mining progresses.
High-angle conveyors can be used to avoid overly long mine conveyors to transport material
from the pit (as shown in fig 3 below).

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Fig. 3 Fully Mobile Systems
1.9. COMPARISON OF IN-PIT CRUSHING SYSTEM TYPES
► Conveyor transport requires a smaller size distribution than truck haulage. While some
marginal ores may be processed by dump leaching without crushing, the majority of ore mined
for conventional processing generally requires crushing. On the basis, it is logical to consider
that the primary crusher may be located in the pit in order to condition ore for conveyor
transport.
► Waste, on the other hand, does not require crushing for truck transport, but does require a
size reduction for conveyor transport, and this is an additional cost burden of waste conveying.
Comparison of different in-pit crushing system are as following tables 1 below:

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Table.1 : Comparison of different in-pit crushing system
IPCC Crushing
Options
Fully Mobile Semi Mobile Fixed
Throughput <10,000 t/h <12,000 t/h <12,000 t/h
Truck Quantity None Low Intermediate
Crusher Type Sizer, Jaw/double
roll crusher
Any Any
Unit Crushing Cost Higher Intermediate Lower
Type Specification
Fixed High Capacity
Typical Gyratory/Jaw Crusher
Rarely Relocated
Commonly Associated With Transport
Tunnel
Semi-Fixed High Capacity
Typical Gyratory/Jaw Crusher
Relocated Every 3-5 Years
Commonly Associated With Transport
Tunnel Or Wide Truck Ramp
Movable Medium-Low Capacity
Typical Twin Roll Crusher or Sizer
Relocated as Required to Follow Shovel
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

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CHAPTER 2
2.1. WORKING OF IN PIT CRUSHER CONVEYOR SYSTEMS
► The opencast mining system adopted in RG OC-II is "In-pit Crusher conveyor technology”
i.e., crushing of overburden and coal inside the quarry by semi-mobile crushers and
transporting them by belt conveyors. Crushing Capacity of Overburden and Coal are 3500t/h
and 1650t/h.The truck carries overburden or coal to Hooper ,capacity of Hooper is 120cu.m.
From Hooper to apron feeder rotates with a speed of 0.3m/s.Under Hooper Spillage conveyor
is provided for additional purpose.
► The Hooper takes to Crushing chamber and crush by double roll crusher and crushing
strength is up to 150 M Pa.Crushing ratio is 1:4 – 1:6.Speed of the crusher is 67rpm.
► After crushing by double rolls the coal or over burden moves to discharge conveyor 1,
speed and width of conveyors are 1.7m/s and 2000 mm.From discharge conveyor 1 to discharge
conveyor 2,speed and width of dc 2 are 2.6m/s and 1600mm.In Discharge conveyor metal
detector and magnetic separator are present to detect the metals and magnets.
► From discharge conveyor 2 to bench conveyor and it takes to CONVEYOR
DISTRIBUTION POINT (CDP).The CDP is the point where OB and Coal output come from
three crushers is distributed optimally. This is done by means of a movable shifting head in the
CDP to divert and separate the OB and Coal streams as per requirement.
► At CDP, by using Shunt Head arrangement, coal is discharged on to coal conveyors where
as OB is discharged on to a separate stream of conveyors for subsequent transportation to
spreaders for dumping.

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2.2. SEQUENCE OF OPERATION
CRUSHER
↓
BENCH CONVEYOR
↓
CONVEYOR DISTRIBUTION POINT (CDP)
↓
CONVEYORS → COAL HANDLING PLANT(CHP)(FOR COAL)
↓
SPREADER(FOR OVERBURDEN)
2.3. DIFFERENT PARTS OF IPCC SYSTEM
Fig.4 : Different parts of IPCC System

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2.4. THE MAIN COMPONENTS OF DOUBLE ROLL SEMI-MOBILE
CRUSHING PLANTS
1. Ramps
2. Feed Hopper
3. Apron Feeder
4. Spillage Conveyor
5. Crushing Chamber
6. Crushing Rolls
7. Discharge Conveyor-1
8. Magnetic Separator
9. Discharge Conveyor-2
10. Metal Detector.
Fig. 5 The main components of IPCC System

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2.5. TECHNICAL DATA OF SEMI MOBILE CRUSHER
OVER BURDEN:
► Crushing Capacity Overburden : 3500 t/h
► Max. OB Feed material size : 1500x1200x1000 mm
► Discharge size of OB : 0-300 mm
COAL:
► Crushing Capacity Coal : 1650 t/h
► Max. Coal Feed material size : 1000x800x600 mm
► Discharge size of coal : 0-200 mm
Feed Bin capacity : 120 Cum
APRON FEEDER TYPE : PAN
► Drive : Hydraulic Motor thro. Planetary Gear
► Power : 190 KW
► Center Distance : 11450 mm
► Gradient : 23 Degrees
► Handling speed : adj. Up to 0.3 m/s
ROLL CRUSHER TYPE : DOUBLE ROLL WITH FIXED
ROLL AND HYD. SUPPORTEDFREE ROLL
► Diameter & length : 2000 x 2200 mm
► Power : 2 x 400 KW
► Speed : 67 rpm
► Drive : Helical Gear box and Thro. V pulleys

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DISCHARGE CONVEYOR 1 TYPE : EP BELT
► Belt Width : 2000 mm
► Speed : 1.7 m/s
► Power : 75 KW
DISCHARGE CONVEYOR 2 TYPE : EP BELT
► Belt Width : 1600 mm
► Speed : 2.6 m/s
► Power : 110 KW
PROTECTIONS:
► Over belt Magnetic Separator
► Metal Detector
► Total wt. of the Equipment : 640000 kg
► Total number of hardex caps(picks) in crusher each roll 48 Nos.
► Cost of each Equipment : Rs 16.50 Cr.
► Total Number of Crushers : 4

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CHAPTER 3
3.1. MAINTENANCE OF CRUSHING PLANT
To carry out the proper maintenance, there should be an inspection team, which make the daily
inspection and report to the planning (maintenance planning) and there should be an execution
team.
Quality of spares is one of the most important for the availability of the ICC system. For Ex.
Bearings, v-belts, bolts and wear plates.
The daily inspection has to be carried out for the following.
► TRUCK RAMPS : Daily inspection for soil accumulation and cracks.
► FEED BIN : Daily inspection for wear plates and bolts.
Note : The wear will be much higher at the bottom of the feed bin & wear plates in this zone
need frequent replacement to protect the mother body.
► APRON FEEDER : Daily inspection of fixing bolts of pans, carrying rollers, return
rollers, drive sprocket segments, drive chain, return idlers, drive & return shaft bearings and
planetary gear box.
Daily inspection of lubrication of all bearing and return roller and guide ways.
► SCRAPER CONVEYOR : Daily inspection of chains, flight bars, end bits, return
rollers, wear plates, drive sprocket, return idlers and all bearings.
► HYDRAULICS : Daily inspection of hydraulic pump, motor, control gear box and hoses.
► LUBRICATION : Daily inspection of grease pumps, lubrication lines.
► ROLL CRUSHER : Daily inspection of Roll chamber and lubrication to bearings, v-
belts and guide ways.
► DISCHARGE CONVEYOR (DC-I) : Daily inspection of conveyor belt, impact,
carrying and return idlers, skirt rubbers, pulleys, gear box and coupling.
► MOBILE CONNECTING CONVEYOR (DC-II) : Daily inspection of conveyor
belt, impact carrying & return idlers, bearings and pulleys, rock box rails.
► MAGNETIC SEPARATOR : Daily inspection of conveyor belt, snub pulleys and for
leakage of oils in gear box and coolant tank.
► STRUCTURE:Daily inspection of the structures for any cracks / damages and to rectify
immediately.

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3.2. PROPER MAINTENANCE
The implementation of proper maintenance should be conducted by means of steps and
measures formed to a strategy which ensures the development and application of a Preventive
and Normal Wear Maintenance system to be applied in the field which leads to
- increase of reliability and availability of the ICC systems in question
- Increase of production
- Lower production costs
- Increase of lifetime of the ICC systems.
PROPER MAINTENANCE CONSISTS OF
- Execution of emergency repairs which have to be carried out immediately in order to
minimize downtime
- Replacement of worn or faulty components
- Execution of trouble shooting
- Ensuring of sound repairs according to technical rules and regulations based on proper
planning and work preparation activities
- Improving of quality standards in order to minimize the stops in the system due to
unscheduled breakdowns
- Determination of required and available materials, spare and wear parts
- Recommendations for procurement of proper tools, quality spare parts and wear parts
- Recommendations to workshop requirements
- Creating history files for each mining machine
- Developing of Preventive Maintenance (PM) and Normal Wear Maintenance (NWM)
plans under consideration of the Production plans.
- Execution of PM and NWM activities (weekly or two weekly scheduled stops for such
activities in co-ordination with the Operation Department
- Performing of inspections on a regular basis in due co-ordination with the mine
operation department
- Improving availability, reliability and utilization of equipment
The Proper maintenance system includes the proper quality of spare parts and wear parts.

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Example: Bearings – usage of SKF bearings in place of NSK bearings.
V- Belts - Changing all the V- belts at a time, imported belts
have better life and even wear.
Wear Plates – It is advisable to use the Hardox plates instead of
Other types.
Bolts - On crusher Roll and Apron Feeder M48 bolts
Imported (OEM) quality is preferred for longer life
and they will not spoil the mother body.

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CHAPTER 4
4.1. CRUSHER
► Crushing is the first step of mineral processing where the ore/rocks from the mine site is fed
to mechanical equipment in order to reduce the size for subsequent stages and thus liberate the
valuable mineral from the gangue. Mostly this stage is dry and can be performed in various
stages (2-4).
► The crushers are used to reduce the size of the ROM ore (as large as 1.5m) to a size that can
be fed to ball mill (as small s 4-6mm). Depending upon the requirement there could be a
primary, secondary, tertiary and quaternary stage. In most of the operations primary stage is
performed at the mine site (surface or underground). Primary crushers are commonly designed
to operate 75% of the available time, mainly because of interruptions caused by insufficient
crusher feed and by mechanical delays in the crusher (Lewis et al., 1976).
► Roll Crushers are compression type crushers, and were once widely used in mining. They
have, within the last 10 or so years, fallen into dis-favor among mining and processing
companies. The probable reason is because the large mines require very large crushed product
output with minimal cost, makes the roll crusher uncompetitive. The roll crushers are not nearly
as productive as cone crushers, with respect to volume, and they do have a little higher
maintenance associated with them. Roll crushers do, however, give a very close product size
distribution, and if the ore is not too abrasive, they do not have high maintenance costs.
► Roll crushers have a theoretical MAXIMUM reduction ratio of 4:1. If a 2 inch particle is
fed to the roll crusher the absolute smallest size one could expect from the crusher is 1/2 inch.
Roll crushers will only crush material down to a minimum particle size of about 10 Mesh (2
mm). A roll crusher crushes using compression, with two rolls rotating about a shaft, towards
the gap between the rolls. The gap between the rolls is set to the size of product desired, with
the realization that the largest feed particle can only be 4 times the gap dimension.
► The particles are drawn into the gap between the rolls by their rotating motion and a friction
angle formed between the rolls and the particle, called the nip angle. The two rolls force the
particle between their rotating surface into the ever smaller gap area, and it fractures

17
from the compressive forces presented by the rotating rolls. Some major advantages of roll
crushers are they give a very fine product size distribution and they produce very little dust or
fines. Rolls crushers are effectively used in minerals crushing where the ores are not too
abrasive and they are also used in smaller scale production mining of more abrasive metal ores,
such as gold. Coal is probably the largest user of roll crushers, currently, though. Coal plants
will use roll crushers, either single roll or double roll, as primary crushers, reducing the ROM
coal. Usually, these crushers will have teeth or raised forms on the face of the roll. (Roll
crushers used for minerals and metal ores have smooth faced rolls)(as shown in fig 6 and in fig
7 below).
4.2. TECHNICAL DATA OF CRUSHER
Total Double roll crushers : 2
Total segments : 2× 12 = 24
Total teeth : 24×4 =96
Crushing Capacity Overburden : 3500t/h
Crushing Capacity coal : 1650t/h
Roll Crusher type : Double roll with fixed roll and hydraulically supported free roll
Diameter & Length : 2000×2200mm
Power : 2 x 400 KW
Speed : 67 rpm
Drive : Helical Gear box and Thro. V pulleys
Rolls gap shims for Overburden and coal : 180mm and 80mm

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Fig. 6 Crusher
Fig. 7 Crusher

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4.3. TYPES OF CRUSHERS
i.DOUBLE ROLL CRUSHER : Suitable for large lump size and large volume and
crushing strength is up to 150 M Pa. Crushing ratio is 1:4 – 1:6.
ii.GYRATORY CRUSHER : Suitable for hard and abrasive material, large lumps
and large volumes and crushing strength is up to 400 M Pa.Crushing ratio is 1:5 – 1:7, the
cost of Gyratory crusher is two times of the Double Roll SMC plant of same capacity and
size also bugger.
iii.IMPACT CRUSHER : Suitable for hard material and low volumes and crushing
strength is up to 175 M Pa.Crushing ratio is 1:20 – 1:50.
iv.HAMMER CRUSHER : Suitable for hard material and low volumes and crushing
strength is up to 175 M Pa.Crushing ratio is 1:50 – 1:100.
v.JAW CRUSHER : Suitable for hard and abrasive material and low volumes and
crushing strength is up to 400 M Pa.Crushing ratio is 1:5 – 1:7
.

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4.4. CRUSHER WORKING LAYOUT

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CHAPTER 5
5.1. CONVEYOR
A conveyor system is a common piece of mechanical handling equipment that moves materials
from one location to another. Conveyors are especially useful in applications involving the
transportation of heavy or bulky materials(as shown fig 8 below). Conveyor systems allow
quick and efficient transportation for a wide variety of materials, which make them very
popular in the material handling and packaging industries. Many kinds of conveying systems
are available and are used according to the various needs of different industries. There are chain
conveyors (floor and overhead) as well. Chain conveyors consist of enclosed tracks, I-Beam,
towline, power & free, and hand pushed trolleys.The belts are steel cord belt conveyor.
► Excellent wear resistance – longer operational lifetime
► Reduced power consumption
► Low elongation
► Excellent handling characteristics – reduced maintenance
► Wide range of top quality covers designed to meet the toughest demands including
abrasion, cutting, fire, cold, oil & grease
► Tensile strengths ranging from 500 N/mm up to 5400 N/mm
► Available in widths from 500 mm up to 1600 mm

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Fig. 8. Conveyors
5.2. SIZE OF THE MATERIAL FOR THE BELT CONVEYING

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► After the blasting in the Mining operations, the material should be crushed in such a way
that, it can be transported by conveyors.
► As per German standards the material to be transported should not be larger than 30% of
the belt width.
► Also for wider belts the max. size of the material should not exceed 350 mm.
5.3. TECHNICAL DATA OF CONVEYORS
Max. Material handling rate : 3500 t/h
Max Coal handle : 1320t/h
Belt speed : 4 m/s
Belt width : 1200 mm
Steel cord belt type : St1250
COVER THICKNESS
Top : 12 mm
Bottom : 6 mm
TROUGHANGLE
Carrying Idler : 40 Degrees
Return Idler : 15 Degrees
Total Number of conveyors : 16
COVER THICKNESS
Top : 16 mm/12 mm
Bottom : 8 mm/ 6 mm

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TROUGHANGLE
COVER THICKNESS
Top : 8 mm
Bottom : 4 mm
TROUGHANGLE
Drive Power : 250 KW & 475 KW

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CHAPTER 6
6.1. CONVEYOR DISTRIBUTION POINT (CDP)
► At present in RG OC-II, 4 nos. 3500TPH for OB /1650 TPH for Coal (3 for OB& 1 for
Coal ) crushers to crush the OB to -300mm size or coal to -200mm and dispatch on to three
streams of 1200mm wide belt conveyors. These three streams are conveying either OB or coal
up to CDP (Conveyor Distribution Point).
► The CDP is the point where OB and Coal output come from three crushers is distributed
optimally. This is done by means of a movable shifting head in the CDP to divert and separate
the OB and Coal streams as per requirement.
► At CDP, by using Shunt Head arrangement, coal is discharged on to coal conveyors where
as OB is discharged on to a separate stream of conveyors for subsequent transportation to
spreaders for dumping(as shown fig 9 below).

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Fig. 9. CDP(Conveyor Distribution Point)
CHAPTER 7
7.1. SPREADER
► Spreaders in mining are heavy equipment used in surface mining and mechanical
engineering/civil engineering. The primary function of a spreader is to act as a continuous
spreading machine in large-scale open pit mining operations.
► The overburden is then delivered to the discharge boom, which transfers the cut earth to
another machine for transfer it to the central collection area where the material will be sorted.
Then the remains of the overburden will be transported to the spreader which then scatters the
overburden at the dumping ground.The material is fed to the receiving belt of the spreader via
a tripper car, which can be moved on rails or crawlers.
► The purpose of the spreader is to receive overburden from the haulage conveyor from the
sorting area and dump it in an orderly and efficient manner.

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► To provide ultimate control, a sensor is installed at the discharge boom to measure the
discharge height. When the desired height is achieved, the crawler track of the spreader moves
in a previously designed path to start a new dump site. The slewing gear of the spreader is
confined by two reversal points on the left and right side, and once the operator specifies these
points, all other changes of direction are carried out automatically.
► When the spreader moves, the tripper car automatically follows. An absolute value
transmitter, installed on the tripper car, continuously displays the position of the shifting path.
The control of the travel gear is used to always position the tripper car in the middle, taking
into account the traveling speed of the two travel gears, the angle position between the receiving
belt of the spreader and the tripper car, as well as the left or right hand side of the belt
conveyor(as shown figure 10 below).
Fig. 10. spreader

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7.2. TECHNICAL DATA OF SPREADER
PRINCIPAL DIMENSIONS
► Overall length : 112.3m
► Overall height : 23.4m
► Overall width : 14m
► Overall wt. incl. Receiving boom : 612750kg
POWER SUPPLY
► Voltage : 6.6 kw
► Input : From Tripper car
► Transformer power : 1000kVA
► Installed Motor power : 730kw
PERFORMANCE DATA
► Belt speed : 4.5m/s
► Travel speed : 9.4m/min
► Min. turning radius : 9m approx.
► Permissible gradient during operation : 1:20
► Permissible gradient during travel : 1:10
► Permissible wind speed during operation : 20m/s
► Permissible wind speed when parked : 35m/s
► Average ground pressure : 126kPa
► High dump normal : 22.5m

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► Max. dump reach : 60m
► Highest/lowest position of discharge boom : +25/5m
► Hoisting speed : 3.5m/min
► Slowing speed : 3.5 to17m/min
► Slewing angle
► Between superstructure & receiving boom : +105Deg+/-5deg
► Between tripper car & receiving boom : +120Deg+/-5Deg
► Ground level diff between Tripper car & spreader in operation : 0 m
► Travel path of rec boom on support carriage of the tripper car : +/-3m
► Cost of Each Equipment : Rs.16 Crores
► Total Number Of Spreaders : 3
CHAPTER 8
8.1. COST PER CU.M FOR TRUCK DUMPING
► No.of dumpers deployed: : 8nos
► Lead : 4 kms
► Lift : 250mtrs
► Capacity of dumper : 36 cu.m
► Total load carried by 8 dumpers: : 36 X 8 =288Cu.m
► Total lead of one dumper up and down : 8Kms
► Total distance for 8 dumpers : 64 Kms
► Approximate speed of each dumper : 22Km/Hr
► Consumption of diesel : 60litres/hour

30
► Approximate time taken to cover 64kms : 3hours approximately
► Total diesel consumption : 180 liters
► Total diesel cost : 180X60Rs =10,800Rs
► Cost/Cum dumping : 10,800/288 Cu.m == 37.50Rs
8.2. COST PER CU.M AGAINST SYSTEM DUMPING
► Approximate capacity of conveyor : 1000Cum/hr
► Time taken to transport 288 Cum : 17.28 minutes
► Total power required for dumping : Crusher power + conveyor power +spreader power
: 1100Kw+3500Kw +440Kw = 5040Kw
► No of units consumed for 17.28 minutes running 1451 units
► Cost of power : 1451 X 5.00Rs = 7257Rs
► Cost/Cum dumping : 7257/288 = 25.19Rs
SAVING RS 12 PER CU.M OB

31
CHAPTER 9
9.1. THE ADVANTAGES OF ICC SYSTEM ARE
► Mining operation will be continuous.
► Improvement in the equipment availability and utilization.
► Elimination of fleet of dumpers will reduce diesel consumption along with saving in
lubricants.
► Saving in foreign exchange required for importing oil.
► With adoption of the technology, it will be possible to work deep deposits.
► High system availability.
► Less operational expenditures(OPEX).

32
► Space for operation - at least 100 m needed for IPCC.
► IPCC lends itself to easy automation.
► Lower maintenance cost.
► Highly reduced road preparation.
9.2. DISADVANTAGES OF ICC SYSTEM
► The initial cost of system is normally higher than that of the truck haulage system,
because the complete conveyor and crusher are bought to start production whereas the
truck fleet can be bought in stages to set up production.
► The mining operation is completely dependent on availability of the conveyors. This
availability is over 95% but a shutdown of one belt can stop the entire production.
► Relocation of the crusher and extension of the conveyor is expensive and requires a
shutdown of the mining operation for a period from 2-3 days.
► Material must be crushed to a size of minus 250 mm before loading onto the conveyor.
► IPCC and shovel do not operate together.
► In-pit crushing required for conveying (hard rock) even if not needed (overburden).
► Less flexible in mining layout.
► Less flexible in capacity.

33
PART II
CHAPTER 10
10.1. LOCATION PLAN OF RG OCP-II

34
► RG OC-IIProject is located in southern extremity of the Ramagundam coal belt. The project
is bound by North latitude 18°37'02" and 18°40'42" and East longitude 79°33'13" and
79°36’43" and forms part of the Survey of India Topo Sheet No 56 N/10.

35
► The project is located adjacent to underground mines GDK 10 and GDK 10A Inclines. The
access to the site is well developed.
► Railway siding facilities are available at RG OC-I CHP (located about 6.7 Km away from
the project).
► Coal is dispatched by belt conveyors to RG OC-I CHP. Merry Go Round facility of NTPC
is available at RG OC-I CHP for dispatch of coal through wagons.
10.2. BRIEF DESCRIPTION
RG OC-II PROJECT:
Project Sanctioned : 06-01-1987
Starting of the Mine : November, 1987
Coal Production started : 1991-92
Mine Area : 570 Ha
OB Excavated Upto 2009-10 : 182.65 M.cu.m.
Coal Extracted Up to 2009-10 : 32.84 M.T
Project completed : December,2009.
10.3. SALIENT FEATURES OF EXTENSION PROJECT

36
Land Requirement as per FR : 2255.90 Ha.
Proposed Land : 2526.58 Ha.
Extractable Coal Reserves : 107.46 Ha.
Total Over Burden : 830.68 M.cu.m.
Gradient of the Seam : 1 in 6
Average Stripping Ratio : 1: 7.73
Required men as per FR : 1763
Rated capacity of Coal Production : 4.0 M.T.
Linkage : NTPC Ramagundam
Life of the mine : 27 Years
Grade : Overall ‘D”
Depth of the quarry (Maximum) : 400 Meters
Technology : Shovel- Dumpers in combination with
In pit crusher conveyor technology
Coal Extracted up to 31.03.2015 : 11.39 MT
OB Extracted up to 31.03.2015 : 67.60 M.cu.m
10.4. GENERAL ARRANGEMENT OF CRUSHER CONVEYOR
TECHNOLOGY AT RG.OC-IIPROJECT

37
Fig.11 General Arrangement of crusher conveyor technology at RG OCP II
Project
10.5. SEMI MOBILE DOUBLE ROLL CRUSHING PLANT AT RG.OC-II
PROJECT

38
Fig. 12 Semi mobile double roll crushing plant at RG OCP II project
10.6. APPLICABILITY OF ICC SYSTEM IN SCCL
► The Conveyor transport system is applicable and economical in the following conditions.
Longer lead distances above 4 kms and higher volumes above 15 mbcm per year and life of
the project is above 20 years.

39
► Higher depths above 150 mts and Steep gradients.
► To facilitate the conveyor system, the in-pit crushing system is used. To spread the
crushed OB evenly, the spreader system will be used. The entire system is known as ICC
system.For the above conditions the ICC systems are more economical in the long run, Eco-
friendly and ensure safety.
► In view of the capacities of the dumpers (100 T) and hydraulic shovels (10-12 cu.mt), the
capacity of the crushing plant is limited to 6000 t/h.
► In case the capacity of the crushing plant is more than 6000 t/h, in such situation higher
capacity dumpers (170 or 220 or 240 T) and higher capacity hydraulic shovels (20 cu.mts.)
are tower be deployed.
► Size of mines getting larger.
► Labor shortages and need to keep manning levels low.
► Strip ration increasing.
► Fluctuating fuel cost.
► New environmental regulations.
► Greater Pressure to reduce operating cost.
► Need to quickly respond to changing market demand.
► Maintain flexibility.
► Ore may go to number of destinations.
► Ore blending and priorities may change.
► Higher mineral prices support and justify the development of larger, deeper pits with
higher waste and/or material movements.
► Soaring oil prices drive shift to less expensive electric power.
► The supply of large truck tires remains difficult.
► Carbon emissions will result in increased mining costs and create an environmental
impact.
► There is an opportunity to improve safety with fewer moving vehicles.

40
► Mining costs are currently escalating rapidly.
► Mine production per man hour can increase dramatically.
► IPCC realizes fully integrated automation processes.
► Less logistics and handling of fuel, oil and parts result in lower costs
10.7. 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 labor cost
► Remote controlled operation.
► IPCC is such a system which reduces the transportation cost there by promising continues
production from the mine.It also reduces lead distance of the dumper and consuming continues
flow of material.Even through its capital investment is high, implementation of IPCC in a mine
reduce fuel cost, provides flexibility in transportation, and save operational cost. IPCC
eliminates complex transportation network in a mine. It reduces the accidents due to
transportation. By considering all above, IPCC is a very effective technology that ensures the
smooth running of mining operations.
► Currently the mining industry is increasing its focus on operational excellence and safety
and conveying is an important part of this.

41
10.8. REFERENCE
[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.
[8] 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.

42
[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.
[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.

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