Professional Documents
Culture Documents
INTRODUCTION
DESIGN OBJECTIVES
METHODOLOGY
Effective flat haul
An effective flat haul (EFH) model was constructed based on
the speed that a haul truck will travel at in various haulage
scenarios. The scenarios considered included straight runs,
bends and corners as well as cases for loaded, unloaded
1. SAusIMM, Student, School of Mining Engineering, University of New South Wales, Sydney NSW 2052. Email: scotty9021@hotmail.com
2. FAusIMM, Lecturer, School of Mining Engineering, University of New South Wales, Sydney NSW 2052. Email: p.hagan@unsw.edu.au
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
19
FIG 1 - Phases of the shovel truck system (after Ercelebi and Bascetin, 2009).
Match factor
The productivity of a truck and shovel operation is mutually
dependent on the truck and shovel configuration in a fleet. If
one of these factors is altered than the overall production can
be enhanced or reduced from the optimum rate. Circuits are
affected by the occurrence of queuing, idling and bunching.
Capacity constraints
The capacity constraint model is a useful theoretical approach
based on average load time and changing total cycle time
which was noted in some instances by Najor and Hagan
(2007) to result in a significant reduction in overall truck
productivity and material movement rate. They further
commented that by accounting for capacity constraints, mine
schedules could better reflect actual fleet capacity. It can be
used to determine the productivity of the circuit based on the
excavator and number of haul trucks.
The total haul cycle time was calculated by adding all four
phases in the haulage cycle as per the approach of Ercelebri
and Bascetin (2009). To simulate the haulage process required
appreciating an excavator had a limiting dig rate. Depending
on the haulage circuit, a point could be reached where the
addition of another truck will have no effect on increasing the
overall production output of the circuit. This behaviour has
been explained through the use of queuing theory proposed
by Ringwald (1987) whereby as more trucks are added to a
circuit, the utilisation of a truck at an excavator approaches
100 per cent. Queuing theory provides a probability factor for
queuing to occur and this when incorporated with the match
factor can result in more reliable fleet optimisation (Burt and
Caccetta, 2007).
Equations 2 and 3 from Carmichael (1987) were used to
predict the production rate of a circuit based on the number
of allocated trucks to an excavator:
-1
Pt = 1 - ;
(r) i E
/in= 0 (n n!
- 1) !
(2)
P = PtCt
Pt
Ct
(1)
(3)
where:
RESULTS
Load and dump times
Statistics on the dump time of the EH4500 haul trucks are
summarised in Table 1. The values shown were obtained
from the MinVu database based on a two-month sampling
TABLE 1
Average dump and loading times for the haul truck and hydraulic excavators.
Dump EH4500
Load EX3600
Load EX5500
Number of loads
8581
793
2023
Sample size
8581
793
2023
93 s (1.55 min)
Standard deviation
24 s (0.40 min)
40 s (0.66 min)
27 s (0.45 min)
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
SELECTION OF AN OPTIMUM TRUCK AND SHOVEL FLEET BASED ON EFFECTIVE FLAT HAUL AND CAPACITY CONSTRAINT MODELLING
TABLE 2
Effective flat haul factors used for loaded and unloaded EH4500 haul truck.
Gradient (%)
FIG 2 - Dump time distribution curve for the fleet of EH4500 haul trucks.
Straight
Bend
Corner
0-4
1.5/1.0
1.5/1.0
3.0/3.0
4-8
1.7/1.3
1.7/1.3
3.0/3.0
8 - 12
4.6/2.0
4.6/2.0
3.0/3.0
-(0 - 4)
1.5/1.0
1.5/1.0
3.0/3.0
-(4 - 8)
1.7/1.3
1.7/1.3
3.0/3.0
-(8 - 12)
3.0/1.7
3.0/2.4
3.0/3.0
Note: first value is loaded condition and second value is unloaded condition.
TABLE 3
Variation in maximum truck speed for different road conditions.
Gradient (%)
Straight (km/h)
Bend (km/h)
Corner (km/h)
40
40
20
4-8
35
35
20
8 - 12
13
13
20
40
40
20
4-8
35
35
20
8 - 12
20
20
20
60
60
20
4-8
45
45
20
8 - 12
30
30
20
60
60
20
4-8
45
45
20
8 - 12
35
25
20
Sharp bend
FIG 4 - Load time distribution curve for the EX5500 excavator.
All
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
30
21
TABLE 5
Comparison of different phases in truck cycle times based on calculated
effective flat haul model and measured times.
Phase in truck cycle (min)
Load
Straight uphill
Loaded haul
Straight downhill
Sharp bend
Grade (%)
Distance (m)
EFH (m)
0-4
942
1413
4-8
477
818
8 - 12
293
1352
0-4
996
1494
Sharp bend
Total
Total time (mins)
Total
Measured time
2.97
6.58
1.37
4.67
15.59
EFH model
2.97
6.38
1.55
4.13
15.03
4-8
445
763
80
240
All
150
300
3383
6380
6.38
0-4
996
996
4-8
445
593
8 - 12
80
160
0-4
942
942
4-8
477
636
8 - 12
293
502
All
150
300
3383
4130
4.13
Return
8 - 12
Dump
Total
Straight uphill
Haul
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
SELECTION OF AN OPTIMUM TRUCK AND SHOVEL FLEET BASED ON EFFECTIVE FLAT HAUL AND CAPACITY CONSTRAINT MODELLING
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
23
TABLE 6
A comparison of operating costs for various equipment types relative
to haul truck costs.
Equipment
Costing
While achieving an efficient high production circuit is
important in terms of equipment utilisation, cost is another
important factor that requires consideration. The costing
models for the EX3600 and EX5500 excavators shown in
Figures 12 and 13 respectively, are based on the relative
operating costs provided in Table 6. These models show
Cost factors
EX5500 excavator
50
EX3600 excavator
30
CONCLUSION
FIG 12 - The effect of truck fleet size on mining cost for different truck cycle
times servicing an EX3600 excavator.
FIG 13 - The effect of truck fleet size on mining cost for different truck cycle
times servicing an EX5500 excavator.
24
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
SELECTION OF AN OPTIMUM TRUCK AND SHOVEL FLEET BASED ON EFFECTIVE FLAT HAUL AND CAPACITY CONSTRAINT MODELLING
ACKNOWLEDGEMENTS
The authors wish to acknowledge Anglo American
Metallurgical Coal for allowing access to the data used in this
study and to conduct field measurements at the site. They
also acknowledge support given by staff at Callide Mine with
helping in organising the site visits and giving access to the
resources needed to generate this paper.
REFERENCES
Burt, C and Caccetta, L, 2007. Match factor for heterogeneous truck
and loader fleets, International Journal of Mining, 21(4):263-270.
Carmichael, D, 1987. Engineering Queues in Construction and Mining
(John Wiley and Sons: New York).
Ercelebi, S and Bascetin, A, 2009. Optimisation of shovel-truck system
for surface mining, The Journal of the Southern African Institute of
Mining and Metallurgy, 10(9):433-439.
Najor, J and Hagan, P, 2007. Improvements in truck and shovel
scheduling based on capacity constraint modelling, in Proceedings
Sixth Large Open Pit Mining Conference, pp 87-92 (The Australasian
Institute of Mining and Metallurgy: Melbourne).
Rai, P, 2000. Optimising shovel-truck combination, Coal International,
5(3):230-231.
Ringwald, R, 1987. Bunching theory applied to minimise cost,
J Construction Engineering Management, 113(2):321-325.
EIGHTH AUSIMM OPEN PIT OPERATORS CONFERENCE / PERTH, WA, 18 - 19 SEPTEMBER 2012
25