In Pit Crushing and Conveying, or IPCC, is a process that removes the traditional truck and shovel approach from open pit mining applications. Instead, shovels deposit ore or overburden directly onto a system of belt conveyors that transport it out of the pit for subsequent processing or dumping.

The arrangement of the in-pit belt conveyor network is ever-changing as mining faces advance, different parts of the ore body are accessed or waste dumps are filled. This results in a complex array of possible operating states, each with their own productivity and cost profiles.

Met Dynamics’ Continuous Mining Operation Simulation (CMOS) solution uses  dynamic modelling techniques to track the continuous material transport and energy consumption of the shifting conveyor networks. This provides a tool for quantifying the benefits and costs of an IPCC solution.


Replacing diesel fueled trucks with electrically powered conveyors can offer significant operational energy cost savings, despite initial capital outlays. 

With good planning, the cost savings can outweigh the loss of operational flexibility granted by mobile trucks.


Comparison of energy consumption, truck-shovel versus IPCC.


The Solution

When  benchmarked against alternate truck-shovel arrangements, the CMOS solution can provide full and fair comparisons to be undertaken in terms of:

  • Capital and operating costs;
  • Greenhouse gas emissions and energy efficiency; and
  • The cost of disruptions, such as missed trucks or in-pit breakdowns, to the mining value chain.

CMOS can be used in the following ways to ensure that the extraction of the resource is optimised:

  • Tracking of ore/waste from extraction through to the point of delivery;
  • Predicting the processing characteristics and recovered value of delivered ore;
  • Scheduling and movement of continuous mining equipment in response to changing orebody characteristics and plant performance;
  • Variable timeframe analysis – real time, accelerated time, Life-of-Mine; and
  • Variable level of application – Order of Magnitude, Prefeasibility, Feasibility, Detailed Design, Brownfield Engineering.