In-Pit Crushing

and Conveying-IPCC
Sandvik is a high-technology engineering group with world-leading
positions in selected areas tools for metal working, advanced materials
technology, and mining and construction. We employ more than
47000 people and are represented in 130 countries.
Sandvik Mining and Construction represents one third of the overall
Sandvik Group and serves a broad range of customers in construction,
mineral exploration, mining and bulk materials handling. Our construction
expertise covers quarrying, tunneling, demolition and recycling, and
other civil engineering applications. Our mining products and services
support customers on the surface and under ground, including coal,
iron, copper and gold mining.

S A N D V I K M I N I N G A N D C O N S T R U C T I O N W W W. S A N D V I K . C O M

Sandvik is a registered trademark of the Sandvik Group

2008 Sandvik

Back to the future

material movement efficiency
IPCC is the use of fully mobile, semi-mobile or fixed in-pit crushers coupled with
conveyors and spreaders (for waste) or stackers (for ore) to remove material from an
open-pit mine. Depending on individual parameters, it can achieve full or partial
replacement of trucks for material transport within and out of a mine. Although
IPCC was originally conceived in the 1970s, it is only now that its evolution and
flexibility are truly producing measurable and sizeable returns.

IPCC IS THE ANSWER FOR TODAY

Higher mineral prices support and justify the development of larger, deeper pits
with higher waste and/or material movements.

Soaring oil prices drive shift to less expensive electric power.

The supply of large truck tires remains difficult.

Carbon emissions will result in increased mining costs and create an

environmental impact.

There is an opportunity to improve safety with fewer moving vehicles.

Mining costs are currently escalating rapidly.

Mine production per man hour can increase dramatically.

IPCC realizes fully integrated automation processes.

Less logistics and handling of fuel, oil and parts result in lower costs.

DID YOU KNOW

that 1 tonne of diesel generates 3.2 tonnes
of carbon emissions when burnt?

Apron Feeder

Heavy-duty crushing
smart conveying

Rock Box

IS IPCC RIGHT FOR YOU?

IPCC could work at your operation if at least some of the following apply :
Gyratory Crusher

CRUSHER WASTE THROUGHPUT VS. ROCK STRENGTH

-450MM TARGET MAXIMUM SIZE
CRUSHER TYPICAL
PERFORMANCE
Double Rolls Crusher
CG 880

10000
8000
6000
SIZER TYPICAL
PERFORMANCE

4000
2000
0
0

50

100

150

200

250

You have a long mine life (more than 10 years).

You have laden uphill hauls or long distances.

Large and steady tonnages of material are being moved.

Electricity price ($/KWh) is less than 40% of diesel net price ($/liter)

No more than three material types.

Your cutbacks can be reasonably wide (>150m/164 yards).

Manpower issues prevail.

Reducing carbon and dust emissions is important.

You want lower operating costs!

Example of Fully-mobile System

IPCC CRUSHING OPTIONS

FULLY MOBILE

THROUGHPUT

<10,000 t/h

<12,000 t/h

<12,000 t/h

TRUCK QUANTITY

None

Low

Intermediate

CRUSHER TYPE

Sizers, jaw/double
roll crushers

Any

Any

UNIT CRUSHING COSTS

Higher

Intermediate

Lower

IPCC CONVEYING OPTIONS

DEDICATED RAMP

CONVEYOR TUNNEL

CONVEYOR ON
HAUL ROAD

CONVEYOR ANGLE

<18

<10

<6

CAPITAL COSTS

Intermediate

Highest

Lowest

FLEXIBILITY

Intermediate

Lowest

Highest

SEMI MOBILE

FIXED

Sizer
CG 850

RELATIVE THROUGHPUT

12000

ROCK STRENGTH MPa

Example of Semi-mobile System

Recent Sandvik Analyses

When the screening criteria indicates that an IPCC may be preferable
to trucking, Sandvik recommends a more detailed study. The following
are examples of various types of studies done for different customers
showing the assorted benefits associated with IPCC.

CUMULATIVE CASH FLOW

[MUSD]

MATERIALS HANDLING CASH FLOW

200

CUMULATIVE CASHFLOW DIFFERENCE

150

While up-front expenditures for IPCC exceed those for

100

trucking, lower operating costs can quickly generate a

positive cumulative cash flow by comparison. In this

50

example a positive cumulative cash flow was generated

Your mines particular mix of conditions will dictate the type of IPCC
application which will be the most advantageous; typically IPCC operating
costs are lower than normal truck/shovel operations. With your best interests
in mind, Sandvik will work with you to determine, for example, whether
you can operate better with semi-mobile or fully mobile systems. Fuel
prices, materials mined, size of the mine and manpower availability need
to be analyzed for the full life of your mine to optimize Net Present Value.
The inherent risks of unforeseen factors affect the predictability of your
operations. A well-designed IPCC system minimizes potential uncertainties.

YEAR

$400

Fuel Price $/l

Discount Rate %

$350
$300
$250
$200
$150
Labour $/hr

$100
$50

Power Cost $/kwh

DIFFERENTIAL NPC $MILLIONS

Investments in your mining operation need to incorporate planning over

many years and even decades. You need to know that, despite larger
short-term capital expenses, your IPCC program will return your investment
quickly through lower operating costs, adding to your profitability early
in your mines life.

within 4 years, with substantial savings beyond year 7.

15

10

-50

IPCC SENSITIVITY ANALYSIS

IPCC SENSITIVITY ANALYSIS

This sensitivity study included the costs for diesel fuel,
electricity, labor and discount rate. Obviously, rising
diesel and labor costs increase the relative advantage of
IPCC, while rising electricity cost and discount rate do
the opposite. The slope is steepest for the diesel cost
curve, meaning that the financial return in this case is
less predictable for trucking than for IPCC.

$
-30%

-20%

-10%

0%

10%

20%

30%

% VARIATION

IPCC RISK PROFILE

Financial

30
25

Community

IPCC RISK PROFILE

20

Environmental

15
10
5
Safety

QUANTITY

IPCC flexibility
defining your productivity

0
LOW
(<30)

MODERATE
(30 to <90)

HIGH
(90 to <300)

RISK SCORE LEVEL

EXTREME
(300 and above)

System risks beyond financial predictability should

also be well understood. Sandvik will work with
you to create a risk profile and give you a complete
picture of IPCC. In this example, there are a small
number of low-level environmental risks, but none
that can be considered extreme.

Sandvik has developed a sophisticated process for analyzing your needs

and objectives, based on desired output and considering your environment,
to give you maximum return. Conceptual charts can give you perspectives
on what IPCC can do, including operating expense reductions of up to
40% let us advise you on what Sandviks system will do for you.

Why Sandvik for your IPCC?

expertise produces results
With over 140 years in helping mines to innovate and maximize productivity,
Sandvik can offer the right mix of products, technical/design expertise, transition
and ongoing support for your specific operations or projects. When you buy
Sandvik components, you get products produced at our own factories. Sandvik
has the widest mining offering of any company, and is an established global
leader in the supply of materials handling systems.
IPCC PRODUCTS
Sandvik designs and provides a full range of IPCC equipment including fully
mobile crushers to 5000t/h, semi-mobile crushers and sizers to 10,000t/h,
primary gyratory crushers to 11,000t/h and conveyors, spreaders and
associated infrastructure to 22,000t/h.
TECHNICAL/DESIGN EXPERTISE
Sandvik has a dedicated technical engineering capability which can work with
your engineers to assess the applicability of IPCC at your operation or project.
With engineering and design support for generation of capital and operating
costs for all IPCC components, we handle everything from proof of concept
studies to operating mine evaluations. Sandvik also specializes in the retrofitting
of IPCC systems for existing truck/shovel pit designs.
TRANSITION
Whether you are considering an expansion or are just starting your operation,
Sandvik will be with you every step of the way, providing assembly, commissioning
and warranty support for the IPCC installation as well as training as required.
LARGEST AFTERMARKET SUPPLY/SUPPORT OFFERING
When applicable, Sandvik provides extensive aftermarket support options for our
IPCC systems, including:

Performance contracts

Parts supply

Assistance with and training for relocating systems

Mine engineering training to optimize mine design for IPCC

Continuous performance
for continuing needs
Sandvik has global experience in over 130 markets which benefits you locally.
We offer service and maintenance customized to your needs. From a world-wide
spare parts system to a dedicated, knowledgeable service team, you can have
confidence in high availability and total support with our system.
You should expect a lot with Sandvik; starting with commissioning and continuing
through the life of your IPCC system, we will work towards a superior performance
level. Audits and inspections will better ensure your productivity, and regular evaluations will focus on enhancing your results. This will include finding ways to extend
product life and help your employees do their jobs safely, properly and easily.
We have a vested interest in your success; our reputation depends on
it. Starting at your first enquiry throughout the existence of the project,
Sandvik will be at your side.