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Farhad Moosakazemi
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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.
Key words: Crushing; Conveying; IPCC; Copper.
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 mines working face.
It is relocated every 1 to 2 years, as required, to maintain the relationship between distance and
elevation from the face [2].
3-2. 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
[8]. Comparison of different in-pit crushing system are as following tables:
6
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
Any
Any
Higher
Intermediate
Lower
Type
Fixed
Semi-Fixed
Relocatable
Movable
Specification
High Capacity
Typical Gyratory/Jaw Crusher
Rarely Relocated
Commonly Associated With Transport Tunnel
High Capacity
Typical Gyratory/Jaw Crusher
Relocated Every 3-5 Years
Commonly Associated With Transport Tunnel Or Wide Truck Ramp
Medium Capacity
Typical Twin Roll Crusher Or Sizer
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
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].
4-1. Types of conveyor systems
For each of the IPCC system options there are ways the conveyor can exit the pit:
A tunnel
A dedicated (generally steep) conveyor ramp
An existing haul road [6].
IPCC Conveying
System
Dedicated Ramp
Conveyor Tunnel
Conveyor Angle
<180
<100
<60
Capital Cost
Intermediate
Highest
Lowest
Flexibility
Intermediate
Lowest
Highest
Typical speed
Typical width
(kt/hr)
(m/s)
(mm)
Fixed
5-12
4-6
1800-2400
Relocatable
5-12
4-6
1800-2400
Type
Shiftable
comments
5-12
4-6
1800-2400
2-4
3-4
1200-1800
0.5-2
3-4
1200-1800
5-12
4-6
1800-2400
Crawler Mounted
Piggy-Back
Tyre Mounted
Piggy-Back
Crawler Mounted
Belt Wagon
good
floor
Energy efficiency - conveying is more efficient than other forms of material transport.
Mine life, up to 50-60 years of operation - need at least four years to pay back capital and
+10 is ideal.
Material movements - need at least 10 Mt/y (prefer 25 Mt) per stage.
Electricity cost versus diesel cost electricity costs ($/kWh) less than 25% of diesel price
($/litre).
Number of material types - co-disposal makes dump development difficult but not
impossible.
Rock strengths - if < 70 MPa then use of sizers or double rolls crushers (DRC) makes
IPCC cheaper in both capital and operating costs but new hybrid DRC can process up to
150 MPa.
Space for operation - at least 100 m needed for IPCC.
Dumping restrictions - any height restrictions? (IPCC dumps can otherwise be formed
much higher in a single pass, with less ancillary equipment needs).
IPCC lends itself to easy automation.
Timing - IPCC is ideally suited to new operations or an expansion, rather than steady state
operation. It is also, generally, capex neutral compared to trucks when taking into account
replacement schedule and operating expenditure is less.
Vertical advance rates - moving crushers more than say twice a year creates a lot of
system downtime at seven days per move.
Gravity - conveyors can generate power on downhill runs.
Truck cycle times - in a mining operation IPCC may not work well below 25 min cycle
times. In a quarry where IPCC is processing ore this can be much lower [9].
Minimal dependency on weather.
Ability to adjust to economic changes quickly.
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 [10].
Substantial saving in civil works.
Lower installation cost than stationary crushing plants.
Flexibility to alter the primary crusher location and conveying scheme as the mine
develops.
Safe mine operation due to less moving equipment [5].
9
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 [3].
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 [4].
IPCC and shovel do not operate together [3].
In-pit crushing required for conveying (hard rock) even if not needed (overburden).
Less flexible in mining layout.
Less flexible in capacity [11].
11
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].
9-4. Gibraltar Mines
This open pit mine in McLeese Lake, B.C. produces 37000 tonnes of copper-molybdenum ore
daily from four pits. In 1980, an in-pit crushing and conveying system was installed in the East
Pit. The system comprises a 1.4 * 1.9 m (54-74 in) gyratory crusher and three flights of
conveyors of a total length of about 10 km and lift of 145m. crushed ore is loaded onto a slow
speed 2.13 m wide discharge conveyor, then transferred onto a 1.5 m wide two-flight overland
conveyor transporting ore to the processing plant. Average capacity of the system is 1800 tonnes
per hour, and during the last five years the system handled 45 million tonnes of ore [15].
9-5. Island Copper Mines
This open pit at Port Hardy, B.C. Canada produces 43000 tonnes of copper ore daily at a
stripping ratio of 2:1. It is a mine which converted its all-truck system into in-pit crushing and
conveying. The new system, installed in 1985, employs a portable crusher station, and out of pit
conveyor which transports ore through an inclined tunnel to the surface facilitates. Waste is still
handled by trucks. Total investment in the entire system was 24.3 million CDN dollars, with
expected saving of $0.19/tonnes. The payback period is 4 years and the truck fleet was reduced
from 25 to 14 units [16].
9.6. Highland Valley Copper
This open pit mine, located in the Highland Valley, B.C., produces 120000 tonnes of
copper/molybdenum ore per day from two pits. Recently, the company has installed two in-pit 1.5
* 2.2 m (60-89 in) gyratory crushers for ore crushing, at a cost of $20 million. Each crusher has a
capacity of 6000 tonnes/h and has its own conveypr system transporting ore to the Lornex mill
over a distance of 2.5 km [17].
12
Fig. 9: In-pit crushing continuous haulage and spreading system at Escondida mine/chile [10].
13
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 Frdertechniks 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.
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