In Pit Crushing and Conveying (IPCC) Systems

Requirements

Customer: Rio Tinto Coal Australia

Rio Tinto Clermont Mine in Central Queensland uses an In-Pit Crushing and Conveying System (IPCC) for a major component of its overburden stripping for the mine. The IPCC consists of a fully mobile sizing rig operating in the upper levels of the pit combined with, a ramp conveyor, 2.5km movable pivoting dump conveyor, and a tripper/stacker on the dump. Future development plans to add further trunk conveyors to expand the transport distance of the system.

As initially installed the IPCC system experienced major materials handling issues from early operation, primarily blocking of transfer chutes on the tripper and stacker.

We were engaged by Clermont to redesign the transfer chutes to improve the material flow characteristics. The chutes needed to handle a variety of overburden products from hard basalt, to sticky clay materials. We also assisted Clermont with a range of other engineering improvement projects on the IPCC system.

Solutions

• Engineering advice and assessments;
• Site Engineering supervision and re-commissioning during major outages;
• Detailed mechanical and structural design of head chute, loading boot, impact plate and spoon for:
  • Stacker and Tripper;
  • Ramp Conveyor; and
  • Hopper Cars.

• Other Engineering Projects:
  • Take-Ups;
  • Runback Checks;
  • Conveyor Powers & Tensions;
  • Low Speed Couplings;
  • Idlers and Pulleys; and
  • Maintenance Equipment.

Benefits

Our work has been a major success for Clermont with a significant reduction in downtime due to chute blockages, and increased output.