In the pursuit of sustainability, the mining industry is increasingly turning towards innovative solutions to reduce its environmental footprint. One such solution involves in-pit crushing and conveying (IPCC) systems, which are widely regarded as more sustainable and efficient alternatives to traditional diesel truck haulage.

However, as the mining sector continues its journey toward decarbonisation, the emergence of battery-electric haul trucks (BEHTs) as a viable alternative to diesel-powered trucks introduces new considerations. BEHTs promise to reduce emissions and align with broader sustainability goals, yet questions persist regarding their scalability, operational efficiency, and cost-effectiveness in large-scale mining operations. This is especially true when compared to IPCC systems, as the industry awaits commercially available BEHTs (greater than 140 t).

There are intricate trade-offs involved; while both offer potential, each presents distinct challenges and benefits, largely influenced by site-specific factors and long-term objectives.

IPCC: A proven solution with room for improvement

IPCC systems have been in operation for years, with several mining companies adopting them to reduce their reliance on trucks and improve efficiency. The central benefit of IPCC is its ability to move material by conveyors, which is more energy efficient. By eliminating the need for trucks, these systems significantly cut down on fuel use and emissions. Additionally, for some sites, IPCC offers improvements in mine closure by creating better landforms for waste material, thus reducing the need for costly dozing activities during mine decommissioning.

A significant advantage of IPCC systems is their ability to provide continuous material transport, unlike the cyclical nature of truck haulage. Trucks, even those powered by batteries, require time to load, haul, and unload, often creating bottlenecks and inefficiencies. Conveyors, on the other hand, ensure steady, uninterrupted material flow from the pit to the processing plant or waste dump. This continuous flow improves material handling operating time, making IPCC a more efficient solution in terms of both time and resources.

However, the technology is not without its challenges. IPCC solutions require considerable capital investment. Given the complexities of the required infrastructure, the upfront costs can make it a challenging decision for many to commit initially. While these systems are capable of delivering long-term operational savings and sustainability benefits, their initial infrastructure demands – including mobile crushers, conveyors, and other equipment – can be prohibitive for some projects.

Moreover, the extent to which IPCC can be fully ‘truckless’ depends on the specific mine site. A fully mobile IPCC system, which would eliminate trucks entirely, may not be feasible for all operations. In many cases, hybrid solutions, which combine IPCC with a smaller truck fleet, may offer the best balance between sustainability and operational flexibility. It really is a case of understanding each site and thinking outside of the typical truck shovel operation.

This is a preview of an article that was originally published in the March 2025 issue of Global Mining Review.

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