References
Kazakhstan
TAKRAF IPCC System Vostochny
Guinea
IPCC and Material Handling System Contract for Simandou Iron Ore Project in Guinea
The successful and on-time delivery of TAKRAF Group's supply contract for the Simandou iron ore project…
In-Pit Crushing, Conveying and Stacking/Stockpiling Systems (IPCC)
TAKRAF Group IPCC Systems: Safer, more sustainable solutions for new and brownfield operations
Key Facts
- Types of plants
- Mobile/semi-mobile/fixed crushing plants
- In-pit or ex-pit crushing
- close to where rocks are blasted and loaded
- Conveying
- up to 50,000 t/h on one conveyor
- Crushing
- up to 14,000 t/h
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What is In-Pit Crushing and Conveying (IPCC)?
In-Pit Crushing and Conveying (IPCC) is a mining method in which material is crushed in or near the mine pit and transported by conveyor systems rather than by conventional truck haulage. By integrating crushing, conveying and stockpiling technologies into a continuous material handling process, IPCC systems can improve operating efficiency, reduce emissions and support long-term mine planning.
In-Pit Crushing, Conveying and Stacking/Stockpiling Systems (IPCC)
In-Pit Crushing and Conveying Systems (IPCC) systems reduce the need for truck haulage to a minimum and build operational resilience. They potentially substantially reduce operational expenditure (OPEX) and, additionally, provide important safety and environmental benefits.
While conventional truck haulage remains the most flexible transport option, it can account for up to 60% of total mining costs. In-pit conveying systems offer an effective alternative by reducing or eliminating large mobile truck fleets on pit access roads, or by replacing long-distance truck haulage to downstream facilities such as stockpiles or waste dumps.
Depending on pit development and well-defined mine plans, fully mobile, semi-mobile or fixed crushing plants can be installed in-pit or ex-pit, typically positioned as close as practicable to the mining face.
Why consider IPCC?
IPCC systems significantly reduce:
- Greenhouse gas emissions by replacing fossil fuel-driven trucks
- Noise levels and dust emissions, as well as water consumption associated with haul road maintenance
- Weather-related downtime when mobile equipment can no longer access inclined ramps
- High overall maintenance costs associated with haulage trucks
- Manpower requirements when autonomously-controlled trucks are not applicable
- Safety gaps due to decreased mobile vehicle use
Implementing an IPCC system
The successful implementation of an IPCC system requires an initial technical feasibility study, based on geological, geotechnical, operational and site-specific conditions, together with a positive life-of-mine economic case that offsets the typically higher upfront capital investment.
TAKRAF Group’s Mining Technology Center evaluates each operation’s IPCC potential through dedicated studies and technical proposals based on:
- More than a century of experience and know-how in continuous mining systems
- A comprehensive IPCC product range from a single source, with only gyratory crushing machines needing to be externally sourced for TAKRAF Crushing Plants
- Mine planning expertise sourced from a global team of specialist mine planning engineers
Designing an IPCC system
Every operation requires an individual assessment. Important design factors include:
- Material characteristics
- Annual throughput
- Haul distances
- Pit geometry
- Elevation changes
- Climate conditions
- Life-of-mine planning
TAKRAF evaluates these parameters during feasibility studies and engineering phases to determine the optimal system configuration.
Why IPCC is becoming increasingly important in mining
As open-pit mines become deeper and haul distances increase, traditional truck-based transport can become less efficient and more costly. At the same time, mining companies face growing pressure to reduce greenhouse gas emissions and improve energy efficiency. IPCC systems help address these challenges by combining high-capacity crushing and conveying technologies into an integrated material handling solution.
Typical applications
TAKRAF IPCC systems are used in large-scale operations including:
These systems are particularly suitable for high-throughput operations requiring reliable and efficient material transportation over long distances.
Supporting sustainability goals
Replacing diesel-powered truck fleets with electrically driven conveying systems can contribute to:
- Lower greenhouse gas emissions
- Reduced fuel consumption
- Lower dust generation
- Reduced noise levels
- Improved energy efficiency
For many mining companies, IPCC systems play an important role in broader decarbonization and ESG strategies.
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Benefits
Cost-effective solutions
Long-term cost advantages are derived from meticulously planned system and equipment selection, based on decades of experience, especially in high-capacity operations.
Reliable operation in challenging operating conditions
TAKRAF’s IPCC equipment is engineered to withstand the harshest conditions from deserts and high-rainfall regions to elevations above 4,000 m asl and the extreme cold of northern climates.
Continuity
TAKRAF’s 300-year heritage gives customers confidence in the Group’s longevity and its ability to support equipment throughout its entire lifecycle.
A key technology for mine electrification
The mining industry is increasingly moving toward electrified operations. IPCC systems support this transition by replacing diesel-based haulage with electrically powered crushing and conveying infrastructure, helping operations reduce both operational costs and environmental impact.
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