{"id":7478,"date":"2024-06-04T18:31:10","date_gmt":"2024-06-04T18:31:10","guid":{"rendered":"https:\/\/northamericanmining.com\/?p=7478"},"modified":"2024-06-04T18:31:33","modified_gmt":"2024-06-04T18:31:33","slug":"to-ipcc-or-not-to-ipcc","status":"publish","type":"post","link":"https:\/\/northamericanmining.com\/index.php\/2024\/06\/04\/to-ipcc-or-not-to-ipcc\/","title":{"rendered":"To IPCC or not to IPCC?"},"content":{"rendered":"\n

We live in a mining industry of ever deepening pits, rising waste-to-ore ratios, and increasing pressure to reduce carbon emissions and other environmental impacts. Although by no means suitable for every mine, in-pit crushing and conveying offers a solution to all of these issues and, where it makes sense, the economic and environmental benefits can be significant.<\/em><\/p>\n\n\n\n

By Jonathan Rowland<\/em><\/p>\n\n\n

\"\"
In-pit crushing and conveying can offer significant economic and environment advantages. Pictured: Terra Nova Technologies modular primary gyratory crushing station at a large copper mine in Chile.<\/em><\/figcaption><\/figure>\n\n\n

In-pit crushing and conveying (IPCC) refers to \u201ca system that combines crushing and conveying technologies to transport material within a mine site as an alternative to traditional truck haulage,\u201d explained Paul Emerson, director of business development at Terra Nova Technologies. The idea is that \u201cconveying material is more efficient \u2013 in terms of energy and cost \u2013 than trucking but, in order to convey material, it must first be crushed, as whole-rock feed will damage the conveyors,\u201d added Phil Morriss, an independent mine engineering consultant and specialist in IPCC analysis.<\/p>\n\n\n\n

As a term, it was \u201ccreated for mining systems with a crushing plant \u2013 preferably semi-mobile or fully mobile \u2013 located directly in the pit,\u201d said Rico Neumann, chief mine planning engineer at TAKRAF GmbH. \u201cBut the meaning has become more general over time. Nowadays, IPCC tends to mean one or more primary and\/or secondary crushing plant(s) in a pit, at pit rim or other nearby location, with a downstream conveying system feeding waste dumps, commodity stockpiles, or intermediate bins for further transport and\/or processing.\u201d<\/p>\n\n\n\n

More often used to handle ore, IPCC can also be used to handle waste streams, although the economics here are more challenging. Yet, as waste-to-ore ratios increase and haulage cycles get longer, \u201cwaste IPCC can offer the chance to decrease costs and enable the economic extraction of ore at greater depths,\u201d said Morriss.<\/p>\n\n\n\n

Three types of IPCC<\/strong>
There are three main types of IPCC system, which are defined by the maneuverability of the crushing station. The least mobile option is a fixed IPCC system, wherein the crushing station \u201cis typically located near the pit rim and is (as the name implies) fixed for the life of the mine,\u201d said MMD\u2019s Puckett. \u201cTrucks then haul material to the station for efficient long haul by conveyor.\u201d<\/p>\n\n\n\n

Semi-mobile IPCC systems involve \u201cportable crushing stations that are frequently relocated closer to the face, as it progresses, by ancillary equipment, such as bulldozer or transporter,\u201d Puckett continued. These periodic relocations, which typically occur either quarterly or biennially, help keep truck haulage distances and economics down. \u201cThe crushing station is mounted on moveable pontoons or skids to facilitate this repositioning,\u201d added Terra Nova\u2019s Emerson, \u201cwith a series of bench conveyors and ramp conveyors then transporting material out of the pit.\u201d<\/p>\n\n\n\n

The final \u2013 and perhaps truest \u2013 iteration of the IPCC concept is the fully mobile system. Here the crushing station is equipped with \u201cpermanently attached, powered tracks or wheels that allow it to follow the face excavation equipment,\u201d said Puckett. \u201cFully mobile systems replace the use of trucks in primary excavation,\u201d added Nicholas Russell, principal mechanical engineer at Worley. \u201cRather, shovels, excavators, or loaders feed directly onto a conveyor system via a dump hopper with a sizer or crusher.\u201d<\/p>\n\n\n\n

Selection between systems \u201cdepends on factors such as mine layout, material characteristics, and production targets, aiming to balance cost, operational efficiency, and environmental impact,\u201d concluded Terra Nova\u2019s Emerson. Mines may also \u201ctransition from semi-mobile to fully mobile operation, or utilize both,\u201d noted Worley\u2019s Russell.<\/p>\n\n\n\n

In terms of the equipment required, IPCC systems generally combine several proven technologies, according to Tarrant Elkington, general manager at Snowden Optiro.<\/p>\n\n\n\n

    \n
  • Crushing: Sizers, double roll crushers, high-bypass jaw crushers, or gyratory crushers, with selection dependent on the strength of the material to be crushed and its particle size distribution.<\/li>\n\n\n\n
  • Conveying: Overland conveyors, generally fixed, and track- shiftable conveyors for waste materials, are usual for fixed and semi-mobile system, Modular conveyors are more frequently used for fully mobile systems.<\/li>\n\n\n\n
  • Spreading\/discharging: Some form of spreading will be required for waste material, using mobile equipment that can transfer material from the conveyors and discharge safely onto the waste dump.<\/li>\n<\/ul>\n\n\n
    \"\"
    Bulk ore sorting (BOS) systems complement IPCC systems, providing analysis, sorting, and separation of ore in the pit, based on<\/em> natural variations within orebodies. Pictured: a MMD BOS application.<\/em><\/figcaption><\/figure>\n\n\n

    Benefits of IPCC: Deeper pits and operating costs<\/strong>
    Returning to our starting point and those pressing challenges facing surface mines today, IPCC systems \u201coffer a multifaceted solution to address these challenges,\u201d said Terra Nova\u2019s Emerson. \u201cWhile initial capital investment is higher, IPCC systems can offer significant long-term operational cost savings through reduced fuel, labor, and maintenance expenses.\u201d<\/p>\n\n\n\n

    \u201cCapital costs are high,\u201d agreed Phil Morriss, \u201cbut in most studies, they are close to the truck purchase and replacement cost over the life of the project, while operating costs are generally considerably lower than trucking alternatives: typical savings are 25% to 40% of a truck-and-shovel operation for the same tonnage.\u201d Much of this benefit derives from the fact that \u201cconveying offers a more energy- and cost-efficient way of transporting material up hill, as conveyors do not have to carry the dead weight of the empty truck.\u201d<\/p>\n\n\n\n

    Conveyors \u201ccan also climb steeper gradients than trucks,\u201d said MMD\u2019s Puckett, an important factor as mines descend to ever deeper depths. \u201cTogether with the reduced bench width needed for conveyors, the use of conveyors can shape a mine very differently to a conventional long haul truck-and-shovel operation. Steeper mines also minimize the amount of overburden that needs to be removed before getting down to the paydirt, not only helping the mining operation, but also subsequent land reclamation.\u201d<\/p>\n\n\n\n

    There is also an efficiency bonus to be gained from adopting IPCC, even when mining operations still include some truck haulage. \u201cReducing truck haulage distance with semi-mobile and fixed IPCC installations means trucks spend more time as a percentage dumping and being loaded, increasing the production rate per truck, and reducing truck numbers compared to full truck-and-shovel operations,\u201d explained Puckett. This flows on to reduced maintenance workshop needs and downtime, noted Snowden Optiro\u2019s Elkington, with trucks able to shift more material between stoppages. IPCC systems can also mitigate, either partially or completely, the need to purchase new trucks.<\/p>\n\n\n\n

    Yet IPCC is not a \u201csilver bullet,\u201d as TAKRAF\u2019s Neumann pointed out. \u201cDeep pits present a real challenge when it comes to relocating the crushing plant into the pit. And as conventional 18-degree conveyors require straight ramps in a normally curved pit wall, additional cuts can increase the generation of waste material. Tunneled solutions might be an option (but these are expensive) or special steep-angle\/suspended conveyors that are independent of access\/haul ramps. A chain of several mobile conveyors, closely fitting along the pit wall, has also been looked at, but this creates other unique challenges in terms of numerous transfer points, increased power consumption, and potential interference with other infrastructure.\u201d<\/p>\n\n\n\n

    Benefits of IPCC: Environmental impact<\/strong>
    The energy efficiency of electrically powered conveyors, especially when paired with renewable energy sources, \u201coffers significant reductions in carbon footprint when compared to traditional haul trucks and thus aligns with miners\u2019 environmental and sustainability goals,\u201d said Terra Nova\u2019s Emerson. Indeed, when coupled with hydropower, IPCC can offer \u201cnear 100% reduction on CO2 emissions per liter of fuel saved,\u201d added Phil Morriss. \u201cOther power sources deliver lower reductions with coal-fired power offering the least or near-zero reduction.\u201d<\/p>\n\n\n\n

    Because conveying is \u201cmore energy efficient than trucking, there is also potential to reduce the overall energy required by the mine, although this may be partially offset by the energy required for crushing in waste IPCC,\u201d continued Morriss. It is a benefit that is \u201conly compounded over longer haul distances,\u201d added TAKRAF\u2019s Neumann.<\/p>\n\n\n\n

    Removing (or reducing the number of) truck diesel engines from the pit also means that \u201cmines become cleaner and quieter, with less dust and less non-carbon emissions. Fully mobile systems typically eliminate trucks, so noise pollution and dust are reduced considerably, while in semi-mobile and fixed installations, truck haulage is limited to the pit. With fewer trucks generating less dust, the need for dust suppression is reduced, lowering water consumption in the mine,\u201d said MMD\u2019s Puckett. There is also \u201cbetter control of material handling and reduced spillage, further minimizing the ecological footprint,\u201d added Terra Nova\u2019s Emerson.<\/p>\n\n\n\n

    Benefits of IPCC: Health, safety and labor<\/strong>
    An additional benefit of IPCC relates to mine safety, which can be \u201cdrastically enhanced by reducing the number of trucks and associated risks of collisions and accidents,\u201d said Emerson. And it is not just the number of trucks that is reduced: \u201cwith less trucks, there is less need for ancillary services, such as graders, bulldozers, and water trucks,\u201d commented Puckett, with Phil Morriss noting a typical achievable reduction of 20% to 30% in grader and dozer requirements.<\/p>\n\n\n\n

    IPCC operations also reduce the number of people in the pit and the cost of labor. \u201cDepending on whether autonomous or manual trucking is used, manpower can be reduced by 2.5 to 6.5 persons per truck removed,\u201d said Morriss. \u201cThis is offset by the manning to operate the IPCC, but this is typically low and largely dependent on scale; hence the larger the tonnage being moved, the higher the net savings in manpower.\u201d<\/p>\n\n\n

    \"\"
    Innovations in fully mobile conveying technology, such as the Super Portable conveyor from Terra Nova Technologies (pictured),<\/em> enable seamless integration with mining operations that have varying needs and dynamic mining plans.<\/em><\/figcaption><\/figure>\n\n\n

    Advancing in IPCC solutions<\/strong>
    All developments \u201cultimately have one aim,\u201d said TAKRAF\u2019s Neumann, kicking off this section of the discussion, \u201cto improve performance and cost models so IPCC comes down on the winning side in trade-off comparisons with other possible material handling systems. In this regard, we have, over the years, seen developments in the layout and design of semi-mobile systems, including the use of modular equipment, designs that reduce civil works, and modifications to improve the speed of crusher relocation to reduce downtime.\u201d<\/p>\n\n\n\n

    Maintainability is \u201canother key issue,\u201d continued Neumann. \u201cCareful and timely preventative maintenance is important for high technical availability. And we shouldn\u2019t forget various developments in the crushing equipment itself, with manufacturers always seeking to increase safety, support higher-capacity throughputs and performance, and reduce power consumption and operating costs.\u201d<\/p>\n\n\n\n

    \u201cWe are excited to see the development of new technologies that assist or complement current IPCC operations in the pit,\u201d said MMD\u2019s Puckett. For example, \u201cour fully mobile Surge Loader (FMSL) acts as a mobile storage bunker between the loader (shovel, front-end loader, screens, etc.) and the truck. This decouples the conventional relationship between the loader and the truck fleet, improving the efficiency and safety of both in semi-mobile and fixed IPCC operations. Looking to the future, the FMSL may also assist with the adoption of smaller electric truck haulage and truck automation.\u201d<\/p>\n\n\n\n

    Another technological development impacting IPCC is bulk ore sorting (BOS), which \u201cprovides in-pit analysis, sorting, and separation of ore, as well as rejection of waste, based on natural variations within orebodies,\u201d continued Puckett. Sorting and discarding waste before downstream processing steps is “already seeing benefits in some operations,\u201d he concluded. \u201cWe are seeing up to 20% uplift in grade, 10% less water and energy usage, as well as lower operating costs and an increase in process system capacity.\u201d<\/p>\n\n\n\n

    \u201cIt sounds counterintuitive but I\u2019m excited for the advancement of autonomous, battery-electric, circa-30 t dump trucks,\u201d Worley\u2019s Russell said, picking up on Puckett\u2019s comments. \u201cThese are perfect to be paired with a \u2018sporty\u2019 semi-mobile dump, crusher and conveyor solution and various forms of BOS. This is most efficient when done on conveyor, while doing it closer to the pit significantly saves in multiple ways, including operating cost, power consumption, disposal costs, and water consumption.\u201d<\/p>\n\n\n\n

    More prosaically, traditional conveyor technology is also advancing, concluded Puckett. \u201cTraditional conveyor technology routes are commonly restricted to straight lines or very large curves; however new technologies are reducing these restrictions. With newer technologies, conveyors are becoming more versatile, facilitating IPCC deployment in much more challenging operations.\u201d<\/p>\n\n\n\n

    And then, there\u2019s digitalization, which is also \u201ctransforming IPCC systems,\u201d according to Terra Nova\u2019s Emerson, \u201coffering advantages in efficiency, safety, sustainability, and decision-making. Key impacts here include real-time monitoring and control of operations, enabling instantaneous adjustments and predictive maintenance, as well as improved environmental monitoring and compliance monitoring through tracking dust, noise, emissions, and energy consumption. Digitalization also aids \u201cintegration with broader mine operations for better planning, coordination, and bottleneck reduction, as well as remote monitoring and control capabilities, minimizing human presence in high-risk areas, continued the Terra Nova expert.<\/p>\n\n\n\n

    Is IPCC right for you?<\/strong>
    For all its benefits, IPCC is not appropriate for all mine sites. Questions to ask include:<\/p>\n\n\n\n

      \n
    • What is the expected life of mine? IPCC typically requires substantial upfront investment and is more suitable for long-life operations.<\/li>\n\n\n\n
    • What annual tonnages are being considered? IPCC generally benefits from higher throughputs to offset\/recover the high capital cost quickly (although this is not a must).<\/li>\n\n\n\n
    • What are the typical truck haulage cycle times\/distances for the material being considered for IPCC?<\/li>\n\n\n\n
    • How will the IPCC system be integrated with existing operations and infrastructure, and what is the compatibility with future mining plans and processing facilities?<\/li>\n\n\n\n
    • Are you considering IPCC for waste or ore? Waste crushing cost is dead money, and hence has a higher operating cost hurdle to overcome than ore, where crushing is completed for trucking operations.<\/li>\n\n\n\n
    • What are the material characteristics, such as hardness, moisture content, and lump size, which influence the selection of primary crushing type, and thus affect the feasibility of the IPCC system?<\/li>\n\n\n\n
    • Feed complexity: IPCC systems are preferred when the feed is stable and simple. When complex material management is required, e.g., blending ores or acid material management for waste, the benefits of IPCC can diminish.<\/li>\n\n\n\n
    • Haul trucks face problems when entering pits on seasonally wet, muddy inclined haul roads. Could this be a major advantage for conveying lines?<\/li>\n\n\n\n
    • What is the unit power cost versus diesel? High power costs diminish the cost differential; high diesel prices will improve the attraction of IPCC.<\/li>\n\n\n\n
    • What discount rate is being applied to an investment
      decision? High (+12%) rates make investment in IPCC systems difficult to get over the line.<\/li>\n\n\n\n
    • What form of electrical power is available and, maybe more importantly, is this available in sufficient quantity to sustain such an operation?<\/li>\n\n\n\n
    • Does the mine have the technical and operational expertise required to manage and maintain IPCC systems effectively, or can they obtain those personnel?<\/li>\n<\/ul>\n\n\n\n

      Ultimately, \u201cno application will tick all the boxes and there are many trade-offs and unique characteristics of each site that need to be considered to determine whether IPCC could\/should be applied,\u201d said Snowden Optiro\u2019s Elkington. \u201cAt the highest level, a company can get a screening analysis undertaken by competent consulting groups. If this screening looks positive, a desktop study can be undertaken. In simple terms, test the water first, and then be prepared to have the mine planning reviewed to move forward with scoping, pre-feasibility, and feasibility level studies.\u201d<\/p>\n\n\n\n

      And this points to an important fact picked up by Worley\u2019s Nicholas Russell. \u201cIPCC doesn\u2019t just \u2018impact\u2019 mine planning; it is a fundamental driver in the mine model, and changes how a mine plan is developed and maintained. IPCC influences the block cost model and thereby the ultimate pit limits. The pit geometry needs to include allowance for ramp conveyors. Balancing ore-to-waste ratio and getting consistent ore grades are mid-term mine planning activities, not short-term. Close coordination is required between the mine planning team and the materials handling design team to achieve a flexible conveyor design that suits the pit geometry and gives the mine planning team the tools they need to develop, modify, and improve the mine plan.\u201d<\/p>\n\n\n\n

      The pit layout and design for IPCC is \u201cgreatly influenced by the conveyor routing and infrastructure to ensure versatile and efficient material movement during each mine phase,\u201d added MMD\u2019s Puckett. \u201cPit geometry, bench heights, and ramp configurations must accommodate conveyors, sizer stations, crossing points, and material transfer points.\u201d<\/p>\n\n\n\n

      The aim is to ensure \u201cuninterrupted material flow and operational continuity,\u201d Puckett continued. \u201cAs the mine progresses, the expansion of the conveyor network and the relocation of crushing stations must be carefully sequenced to maintain seamless operations. To facilitate this, it may be necessary to implement multiple smaller stations and conveyors strategically, ensuring continuous production to meet extraction targets. Additionally, contingency plans must be devised to address any unforeseen challenges and guarantee operational continuity throughout the mining lifecycle.\u201d<\/p>\n\n\n\n

      The future of IPCC?<\/strong>
      IPCC for ore applications \u201cwill continue to be attractive, given that you are only really incurring the cost of the conveying system,\u201d said IPCC expert, Phil Morriss. \u201cIt just makes sense to bring the crusher as close to the source as possible. And as more mines implement renewal energy solutions, and equipment suppliers find innovative solutions to reduce the capital costs of these systems, we expect that IPCC will become more attractive.\u201d<\/p>\n\n\n\n

      The global push for sustainability and environmental responsibility means the \u201cintegration of IPCC systems with renewable energy sources could become increasingly prevalent,\u201d agreed Terra Nova\u2019s Emerson. \u201cHowever, widespread adoption of IPCC systems faces challenges, such as the difficulty of implementing them in existing mines designed for truck-and-shovel operations. Additionally, the need for versatile and mobile IPCC systems that can adapt to dynamic mining plans, as well as the limitations of existing conveying technologies for steep pit walls, remain obstacles.\u201d<\/p>\n\n\n\n

      In the short term, \u201cI anticipate a focus on flexibility, modular designs, and customization of existing technologies to tailor IPCC systems to the specific operational, environmental, and economic objectives of each mine,\u201d continued Emerson. \u201cMeanwhile, the integration of AI-driven technology represents a promising frontier for IPCC systems, offering the potential for smarter, safer, and more efficient mining operations in the future.\u201d<\/p>\n\n\n\n

      For TAKRAF\u2019s Neumann, this could open opportunities for mine plans that integrate the benefits of IPCC with truck-and-shovel operations. Such systems offer \u201chigh flexibility in the pit area, which is often restricted, as well as the least amount of waste rock per ton of ore, combined with the safe and continuous operation of a conveying system boasting high availability and utilization, together with low operating costs. This is the future of IPCC.\u201d<\/p>\n\n\n\n

      \u201cWhile the journey towards widespread adoption of IPCC systems in the mining industry may present challenges, the opportunities and benefits they offer in terms of efficiency, sustainability, and cost savings are undeniable,\u201d continued Emerson. \u201cUltimately, successful implementation of IPCC systems will require close collaboration between equipment suppliers, mine operators, and engineering firms, facilitating the sharing of best practices, innovation, and technology development.\u201d<\/p>\n\n\n

      \"\"
      The fully mobile Surge Loader\u2122 from MMD decouples loader and truck operations, improving the efficiency and safety of both, in semi-mobile and fixed IPCC operations.<\/em><\/figcaption><\/figure>\n\n\n

      This was echoed by MMD\u2019s Puckett: \u201cNew innovations emerging in mining, especially developments in the pit, will significantly improve the efficiency and sustainability of IPCC operations. However, these innovations only become meaningful when all the parts of the process work harmoniously together, bringing both upstream and downstream benefits.\u201d<\/p>\n\n\n\n

      New collaborations among stakeholders, including technology providers, mining companies, and researchers, are \u201cparamount to an effective solution,\u201d continued Puckett. \u201cInvolving all those involved in the mining value chain is important to ensure the solution accommodates the different undertakings present in a mine, from mine managers through to operators and maintenance crew. Without this involvement, the operation and integration of the equipment within the application may not be fully realized, and its potential never reached. By taking a holistic view of the whole value chain, together with collaboration and modularity, mines can not only enhance efficiency, but also increase agility and operational resilience in the face of evolving challenges.\u201d<\/p>\n","protected":false},"excerpt":{"rendered":"

      We live in a mining industry of ever deepening pits, rising waste-to-ore ratios, and increasing pressure to reduce carbon emissions and other environmental impacts. Although by no means suitable for every mine, in-pit crushing and conveying offers a solution to all of these issues and, where it makes sense, the economic and environmental benefits can be significant. By Jonathan Rowland…<\/p>\n","protected":false},"author":8,"featured_media":7483,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"om_disable_all_campaigns":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_themeisle_gutenberg_block_has_review":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":false,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2},"jetpack_post_was_ever_published":false},"categories":[4],"tags":[1773,2938,613,2937],"coauthors":[1635],"class_list":["post-7478","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features","tag-bulk-ore-sorting","tag-in-pit-crushing-and-conveying","tag-mining-industry","tag-terra-nova-technologies"],"aioseo_notices":[],"aioseo_head":"\n\t\t\n\t\n\t\n\t\n\t\n\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t