Key Benefits

  • Reduce OPEX
  • Reduce CO2 emissions
  • Increase efficiency
  • Increase mine safety

Sustainable and economical IPCC solutions

In open pit mining two different options for extracting and hauling material have been established. On the one hand, shovel and truck only, and on the other hand, in-pit crushing and conveying (IPCC). Energy efficiency and minimising operation costs are the main decision factors when choosing mining technology. Which type is preferable depends on a host of factors, but clearly there is an optimised solution for OPEX and CO2 emissions.


Since mining companies are looking to cut their emissions due to their own environmental responsibility, social pressure or regulatory requirements, alternatives are examined for every new project, every expansion and even brownfield projects. We are working with them to show the potential cost-benefit and emission reductions that in-pit crushing and conveying can deliver.


How in-pit crushing and conveying supports greener mining at Vale’s S11D Eliezer Batista complex.


Mine planning and pre-feasibility studies

From the initial stages of each project, our in-house mine planning team can provide conceptual or pre-feasibility studies on total cost of ownership in relation to planned capacity, selection of the most suitable equipment and mine development/expansion options, particularly when directly comparing in-pit crushing and conveying with shovel and truck operations. Recent studies also consider the implementation of battery-powered haul trucks into IPCC. Traditionally, diesel trucks are used for the "first mile" from the shovel to the primary crushing station, but IPCC is not limited to the diesel truck shuttle. Future developments will show the way forward to battery-powered trucks, which can also be used for this task to achieve an all-electric mine with the highest efficiency and lowest carbon footprint.


Primary crushing stations

IPCC allows for reducing truck haulage in mines by moving the primary crusher closer to the shovel operating area for crushing and conveying of Run-of-Mine (ROM) material. Built on decades-long experience and numerous references around the globe in all climate zones and with different site characteristics, our primary crushing stations can achieve throughputs as high as 14,000 tph – be it in the usual stationary design or in the more flexible semi-mobile configuration. The latter are built on a steel base that rests on a pontoon so that no concrete is required between the crushing station and the ground. The units can be relocated using transport crawlers or self-propelled modular transporters. While our direct-fed crushing stations are equipped with gyratory crushers, the indirect-fed stations can use any type of primary crusher model, including gyratory crushers, Eccentric Roll Crushers ERC®, ABON™ sizers, and more.


Learn more about Primary Crushing Stations.


Find out how IPCC cuts costs and emissions at a large copper mine in Kazakhstan.


High performance overland conveyors

When it comes to transporting run-of-mine (ROM) material over long distances, mine operators are increasingly realising that belt conveyors are the most efficient means of doing the job. There are obviously good reasons why belt conveyors have proven their efficiency in the mining industry for decades. Compared to other means of transport, they offer the highest safety standards, reduced OPEX, and the lowest energy consumption. While trucks use more than 60 % of their energy to move themselves, belt conveyors use on average more than 80 % of the energy they consume to do what they are supposed to do - namely move the mined material. In addition, a conveyor never runs empty, except during the cold commissioning phase or sometimes during maintenance, while mining trucks have to make empty runs where they only move their own weight.

In the end, IPCC reduces the number of haul trucks in the mine and thus the volume of traffic. The reduced number of trucks leads to the reduction of OPEX and CO2 emissions. But most importantly the need for fewer truck operators reduces the number of people exposed to hazardous areas and also reduces the likelihood of human mistakes.


Learn more about safe and reliable mechanical conveying systems.

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