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IPCC Concept

Snowden has completed 18 studies on In-Pit Crushing and Conveying (IPCC) systems in the last 3 years for various mines. These have included scoping, pre-feasibility, and feasibility studies. Snowden has also conducted workshops and published papers on IPCC. Implementing IPCC systems can provide benefits such as reducing haul distances and truck fleet sizes, lowering costs, and allowing pits to reach greater depths.

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Tapadev Das
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291 views24 pages

IPCC Concept

Snowden has completed 18 studies on In-Pit Crushing and Conveying (IPCC) systems in the last 3 years for various mines. These have included scoping, pre-feasibility, and feasibility studies. Snowden has also conducted workshops and published papers on IPCC. Implementing IPCC systems can provide benefits such as reducing haul distances and truck fleet sizes, lowering costs, and allowing pits to reach greater depths.

Uploaded by

Tapadev Das
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Maximise your project value

Discover the best strategy at the start

In-pit Crushing and Conveying


(IPCC)

Alan Cooper Principal Consultant, Snowden Group


acooper@snowdengroup.com
Sandvik Mining and Construction
Snowden Mining Industry Consultants

Recent Snowden IPCC Studies


Snowden (in conjunction with Sandvik Mining and Construction (Sandvik))
has completed 18 IPCC studies in the last 3 years:
Scoping studies:
- El Morro
- Los Bronces
- Antamina (2 studies)
- Olympic Dam
- Tarkwa
- Collahuasi

- Shebas Ridge (2 studies)


- Cerrejon (coal)
- Wahana (coal)
- Spinifex Ridge
- Penyasquito
- Pisolite Hills

Pre-feasibility studies:

Elkview (coal)
Antamina

Feasibility studies:

Antamina

Study updates:

Antamina
Olympic Dam

Snowden and Sandvik have also run five IPCC workshops and have
presented and published a number of papers on IPCC.
Sandvik Mining and Construction
Snowden Mining Industry Consultants

Let me tell a story Part 1


Recently we complete a short scoping study (~2 weeks)
for a rather large open pit in Australia
We got a good result We could have done better if we
had more time But we were happy
The client was not! They spend the next six months using
multiple consultants to disprove the work
They found fault in places but not in the savings
The company had a rethink
Perhaps IPCC is the way to go
Why? It solves a couple of big problems
Let me explain
Sandvik Mining and Construction
Snowden Mining Industry Consultants

Let me tell a story Part 2


Mining companies dont like change They want truck and
shovel because they are familiar with it So IPCC is
unwelcome
But they have a problem:
They will have to go underground in the future and they dont
like that even more
They have to get their accident rate down and most
accidents involve trucks
They just cannot get people

They are starting to like IPCC because:


It has a lower incremental cost and allows the pit to go
deeper , much deeper They can avoid going underground
IPCC need less trucks
IPCC needs less people

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Why are we interested in IPCC?


Diesel fuel prices remain at historical highs
Labour shortages and need to keep manning levels low
Tyre supply and costs
The potential impact of emissions and carbon trading
Changes to the design of semi-mobile IPCC components
But, IPCC needs a reliable (and low cost) electricity supply
After many studies I can say:
If the truck cycle time is greater than 25 minutes then
IPCC will work
Sandvik Mining and Construction
Snowden Mining Industry Consultants

What types of IPCC systems are there?


There are three types of IPCC system strategies that could be developed.
These are:
1. Semi-fixed (or fixed),
2. Fully mobile, and
3. Semi-mobile.
Fixed systems are typically ex-pit and are designed to reduce haulage
distances to the waste dump (or plant for ore). Semi-fixed may be in-pit but
fixed within a pit stage.
Fully mobile systems are based on sizers and limited to softer rocks and the
shovel capacity (~5,000tph).
Semi-Mobile systems are suited to harder rocks and higher capacities (up
to 10,000tph).
We will focus on the retrofit of IPCC to existing hard rock open pits
Sandvik Mining and Construction
Snowden Mining Industry Consultants

The Main IPCC Components


(image curtsey of MMD)

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Sandvik/MMD Semi-Mobile Sizers 5500tph


at Mae Moh Mine, Thailand
Bridge type feeder
for 5500TPH Sandvik
structure using MMD
sizer 4 units at Mae
Moh coal mine in
Thailand
5500tph capacity
twin 190 tonne truck
tiphead

Sandvik Mining and Construction


Snowden Mining Industry Consultants

A 20,000tph Slewable Spreader

Discharge boom

Transfer Bridge

50m
>50m

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Tripper Car

How should the conveyor exit the pit


For each of the IPCC system options there are three
ways the conveyor can exit the pit:
1. A tunnel,
2. A dedicated (generally steep) conveyor ramp, or
3. An existing haul road.
Generally we have found that for most situations the conveyors
should be designed to exit the pit by the haul roads.
We have not found a simple or practical way to integrate
(advance) dedicated conveyor ramps into pit stage designs.

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Semi-Mobile Crusher Access


Semi-Mobile IPCC using temporary access ramp.

TurningArea..
No Accessto Exit Pit Ramp

Shovel Face

CrusherStation

TEMPORARYRamp

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Shovel Face

Semi-Mobile Crusher Access


Semi-Mobile IPCC using temporary access ramp.
Apron feeder + dump
pocket

Ramp Conveyor

Temporary Ramp

Crushing Station

SandvikTransfer
Mining and
Construction
Conveyor
Snowden Mining Industry Consultants

Haul Road Considerations


Minimum practical two way haul road width including a conveyor

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Semi-Mobile Crusher Access


Semi-Mobile IPCC using a permanent location on the haul road.
Crusher Station

Conveyor Access Ramp Slot

Catch Berm

Conveyor
Bridge
Permanent Ramp System
Up to Crusher Station
& Waste Dumps

Down Ramp Direction

Ramp Turning Area


onto Crusher Tip Head
Shovel

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Semi-Mobile Crusher Access

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Big Pit - Semi-Mobile IPCC


Semi-Mobile IPCC using a wide haul road.

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Big Pit - Semi-Mobile IPCC


Semi-Mobile IPCC using a wide haul road.

Sandvik Mining and Construction


Snowden Mining Industry Consultants

High Level IPCC Strategy for


Hard Rock Metalliferous Mines
Two Stage Approach
Stage 1:

Retrofit/Adapt IPCC to the existing open pit operation


Co-exist with Truck and Shovel
Focus on high tonnages
Focus on waste only
Sandvik Mining and Construction
Snowden Mining Industry Consultants

High Level IPCC Strategy for Hard


Rock Metalliferrous Mines
Two Stage Approach
Stage 2 - Adapt/Optimise future cut backs to better suit
IPCC:

Straighten walls
Enlarge cut-backs
Consider other crusher assess options
Consider ore conveying
Sandvik Mining and Construction
Snowden Mining Industry Consultants

Mine Planning Heresy Ignore Whittle

We do not need to follow the Whittle shells religiously


We can straighten the walls and merge the shells to make bigger cut backs
Sandvik Mining and Construction
Snowden Mining Industry Consultants

Waste Dump Development


IPCC waste dumps differ from truck waste dumps in a number of
respects:

The location of the dump does not need to be immediately adjacent to

the pit exits as the incremental haulage costs of conveyors are minimal.

In general, there is no dump (construction) height restriction due to the


risk of crest failure as the spreader can stand far back from the dump
edge.

Dumps are often, but not necessarily, developed in semi-circular arcs

with track shiftable conveyors.

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Waste Dump Development


Semi-circular waste dump development

Direction of rotation

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Another short story


IPCC is sneaking in the backdoor:

In nearly all the studies we do now, the process


people know that the primary crusher should be
moved from the plant to the pit edge

This is what we call the Ex-Pit Crushing and


Conveying (EPCC)

It will not take them long to discover that even


more savings can be made by moving the
crusher 80-100 m down the main pit ramp

Sandvik Mining and Construction


Snowden Mining Industry Consultants

Thank you - Questions


Semi-Mobile IPCC coming to a pit near you!
Please consider IPCC in your next study
It may save you money

Sandvik Mining and Construction


Snowden Mining Industry Consultants

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