2. Contents
◦ Introduction
◦ Definition of in-pit crushing and conveying (IPCC) system
◦ In-pit crushing system
◦ Types of in-pit crushing systems
Fixed or semi-fixed systems
Semi-mobile systems
Fully mobile systems
◦ IPCC system advantages
◦ IPCC system disadvantages
◦ Conclusion
◦ Refrence
3. ◦ Currently the mining industry is increasing its
focus on operational excellence and safety
performance. 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.
◦ In 1956, the first mobile crusher was installed
in a limestone quarry in Hover, West Germany.
1. Introduction
4. 2. 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.
7. 3. In-pit crushing system
◦ 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.
◦ 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. the move coincides with
a general mine holiday period.
◦ The crusher is located next to an embankment, so that truks are able to dump
the material directly from the embankment into the hopper/feeder above the
crusher. Under an alternative arrangment, the crusher is located closer to the
centre 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.
8. 3-1. Types of in-pit crushing systems
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 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.
Fig 3: Fixed In-Pit system [3].
9. 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-mobille systems 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 mining advances, the hauling distance to the
crusher increase, eventually requiring the crusher and
conveyors to be relocated.
10. Fully mobile systems
◦ Fully mobile systems are based on sizers 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. Fig 5: Fully mobile
system [5].
11. Fig 6: High-angle conveyors
Fig 7: Comparsion slope of ramps in
conventional & in-pit system
12. 4. IPCC system advantages
◦ Lower maintenance cost.
◦ Highly reduced road preparation.
◦ Major environmental advantages due to:
◦ Electrically driven motrs versus burned fuel.
◦ Prevention of dust on the haulage route.
◦ In total less consumption of energy and
consumables.
◦ Substantial saving in civil works.
◦ Safe mine operation due to less moving
equipment.
13. 5. IPCC system disadvantages
◦ The initial cost of system is normally higher
than that of the truck haulage system.
◦ Material must be crushed to a size of minus
250 mm before loading onto the conveyor.
◦ IPCC and shovel do not operate together.
◦ Less flexible in mining layout.
◦ Less flexible in capacity .
14. 6. Conclusion
◦ High capacity
◦ Long mine life
◦ Deeper pits
◦ Longer haulage distance
◦ High fuel cost
◦ High labour cost
◦ Remote controlled operation.
15. 7. Refrence
◦ In-pit crushing and conveying-gathering momentum, 2011, International
Mining.
◦ Frizzell, E.M. & Martin,T.W. 1990, In-pit crushing and conveying, Chapter
13.5.
◦ Scot Szalanski, P.E., 2009, Optimizing in-pit crusher conveyor performance,
P&H Mining Equipment.
◦ 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.
◦ Koehler, F., 2010, In-pit crushing looms the way into Australia, Mining
Magazine Congress.
◦ In-pit crushing and conveying (IPCC), 2010, Alan Cooper-Principal
Consultant, Snowden Group.
