Kusmunda Mine Traffic Simulation Simulation

Mine Traffic SimulationKusmunda Mine

SECLMano KanthanathanCommercial Consultancy Services mano@ccsstrategy.comwww.flexsim.comDecember 16, 2014

Objectives

• Build a 3D Traffic Simulation Model for the Kusmunda Open Cast Mine to:

– Analyze traffic congestion at various intersection points

– Identify vehicle bottlenecks at Weigh stations and Load zones

– Model scenarios for traffic for varying truck numbers, truck speeds, road lanes, safety distance, capacities and loading times – Base and 4 Scenarios

– Model scenarios for different calendar time periods (days, weeks, months or year) for mine throughput in tons for Coal and Waste for each route

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• Vehicles waiting at – Intersections

– Load zones

– Weigh bridges

• Mine output for Coal and OB• Scenario Comparison

Traffic & Mine Performance Metrics

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Safety distance and intersection rules enforced in all truck movements

• 2d CAD layout for Kusmunda mine with all intersections, load zones, dump zones, weigh bridges marked

• Schedule of number of trucks entering each route• Route details from parking lot to load zones, dump zones and break areas• Safety distance• Truck speeds for different gradients• Loading and Weighing process times• Intersection rules• Truck capacities• Shift timings

Mine Model Input Parameters

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Mine Model Logic Development

Custom logic developed for Traffic simulation for:– Intersection logic for right of way, priority and stopping distance– Importing road coordinates in 3d space and building 3d road layout from 2d CAD file– Safety distance enforcement– Road surface below road paths– Truck movements for loading, unloading, driver breaks and weighing– Truck scheduler– Speed control of trucks based on differing gradients– Coal and OB output graphs– Intersection, Weigh bridge and loading congestion graphs

Commercial Consultancy Services – Bangalore, India

Kusmunda Mine Simulation Model

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• Base Scenario or ‘As Is’ Scenario• Scenario 1

– 50% more SECL vehicles for OB– One more loader– No SMAS OB vehicles

• Scenario 2– 50% more SECL vehicles for OB– One more loader– No SMAS OB vehicles– Two lane roads for OB removal

Scenarios Examined for Kusmunda Mine

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• Scenario 3– 50% more Contractual Vehicles for Coal & OB

– No SECL vehicles

– One more loader in each route for Contractual vehicles

• Scenario 4– 50% more Contractual and SECL Vehicles for Coal & OB

– Sub scenario 1 – One more loader in each route

– Sub scenario 2 – No change in loader

Scenarios Examined for Kusmunda Mine – contd.

Commercial Consultancy Services – Bangalore, India

Commercial Consultancy Services – Bangalore, India

TOTAL SMAS OBSMAS COAL ESM1 ESM2

MAHAVIR COAL

ROAD SELL BCM AKT SECL LOADER

BASE SCENARIO 272 45 25 60 10 14 55 10 15 38 NO CHANGE

SCENARIO 1 240 0 25 60 10 14 55 10 15 51 ONE MORE LOADER

SCENARIO 2 240 0 25 60 10 14 55 10 15 51 ONE MORE LOADER

SCENARIO 3 351 68 38 90 15 21 83 15 23 0ONE MORE LOADER IN ALL CONTRACT ROUTES

PERCENT INCREASE 29%

SCENARIO 4A and 4B 408 68 38 90 15 21 83 15 23 57

ONE MORE LOADER IN ALL CONTRACT AND SECL ROUTES

PERCENT INCREASE 50%

Scenarios – Truck Numbers & Loader

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Base Scenario

Traffic Congestion – Intersection – Base Scenario

Congestion observed at:– SJ1, SJ19, SJ22 & QJ2 – with average vehicles waiting:

• SJ1 – 35 vehicles• SJ19 – 19 vehicles• SJ22 – 73 vehicles• QJ2 – 14 vehicles

– All intersections marked in layout

If required congestion can also be measured inamount of time each vehicle waits at intersection!

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Traffic Congestion – Load Zones – Base Scenario

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Traffic Congestion – Weigh Bridges – Base Scenario

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Mine Output – Coal – Base Scenario

Commercial Consultancy Services – Bangalore, IndiaTotal Coal Output - yearly estimate is around 20.7 Million tons

Mine Output – OB – Base Scenario

Commercial Consultancy Services – Bangalore, IndiaTotal OB Output yearly estimate is around 23.9 Million tons

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Scenario 150% more SECL vehicles for OBOne more loaderNo SMAS OB

Traffic Congestion – Intersection – Scenario 1

Congestion observed at:– QJ2 for OB vehicles is 16 vehicles

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Mine Output – Coal – Scenario 1

Total Coal Output - yearly estimate is around 23 Million tonsCommercial Consultancy Services – Bangalore, India

Mine Output – OB – Scenario 1

Total OB Output yearly estimate is around 27.9 Million tonsCommercial Consultancy Services – Bangalore, India

Commercial Consultancy Services – Bangalore, India

Scenario 250% more SECL vehicles for OBOne more loaderNo SMAS OBTwo lane roads for OB removal

Traffic Congestion – Intersection – Scenario 2

Congestion observed at:– QJ2 intersection for OB for SECL vehicles is 9 vehicles

which is reduced from 16 vehicles because of usinga two lane road

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Mine Output – OB – Scenario 2

Total OB Output yearly estimate is around 27.3 Million tons – slightly less than Scenario 1Commercial Consultancy Services – Bangalore, India

Conclusion is that adding a road in a part or section of the mine will not necessarily increase the output of Coal or OB, as bottlenecks in other sections of the mine will prevent an increase in output from occurring.

Mine Output – Coal – Scenario 2

Total Coal Output - yearly estimate is around 23.2 Million tons – almost same as Scenario 1Commercial Consultancy Services – Bangalore, India

Conclusion is that adding a road in a part or section of the mine will not necessarily increase the output of Coal or OB, as bottlenecks in other sections of the mine will prevent an increase in output from occurring.

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Scenario 350% more Contractual Vehicles for Coal & OBNo SECL vehiclesOne more loader in each route for Contractual vehicles

Traffic Congestion – Intersection – Scenario 3

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Congestion increase from Base scenario observed at:– SJ1, SJ19 & SJ22 – with average vehicles waiting:

• SJ1 – 42 vehicles from 35 vehicles• SJ19 – 21 vehicles from 19 vehicles

• SJ22 – 91 vehicles from 73 vehicles

Mine Output – Coal – Scenario 3

Total Coal Output - yearly estimate is around 19.4 Million tonsCommercial Consultancy Services – Bangalore, India

ROADSELL may be limited by traffic

congestion as compared to ESM1

Mine Output – OB – Scenario 3

Total OB Output yearly estimate is around 6.5 Million tonsCommercial Consultancy Services – Bangalore, India

Commercial Consultancy Services – Bangalore, India

Scenario 450% more Contractual and SECL Vehicles for Coal & OBSub scenario 4A – One more loader in each routeSub scenario 4B – No increase in loader

Traffic Congestion – Intersection – Scenario 4A

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Congestion increase from Base scenario observed at:– SJ1, SJ22 & QJ2 – with average vehicles waiting:

• SJ1 – 59 vehicles from 35 vehicles• SJ22 – 95 vehicles from 73 vehicles

• QJ2 – 19 vehicles from 14 vehicles

Mine Output – Coal – Scenario 4A

Total Coal Output - yearly estimate is around 28.7 Million tonsCommercial Consultancy Services – Bangalore, India

Mine Output – OB – Scenario 4A

Total OB Output yearly estimate is around 32.8 Million tonsCommercial Consultancy Services – Bangalore, India

Traffic Congestion – Intersection – Scenario 4B

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Congestion increase from Base scenario observed at:– SJ1, SJ22 & QJ2 – with average vehicles waiting:

• SJ1 – 57 vehicles from 35 vehicles• SJ22 – 93 vehicles from 73 vehicles

• QJ2 – 18 vehicles from 14 vehicles

Mine Output – Coal – Scenario 4B

Total Coal Output - yearly estimate is around 28 Million tonsCommercial Consultancy Services – Bangalore, India

Mine Output – OB – Scenario 4B

Total OB Output yearly estimate is around 31.4 Million tonsCommercial Consultancy Services – Bangalore, India

Commercial Consultancy Services – Bangalore, India

Scenario Summary

Annual Output Coal Annual Output OB

Base Scenario 20.7 Million tons 23.8 Million tons

Scenario 1 23 Million tons 27.9 Million tons

Scenario 2 23.2 Million tons 27.3 Million tons

Scenario 3 19.4 Million tons 6.5 Million tons

Scenario 4A 28.7 Million tons 32.8 Million tons

Scenario 4B 28 Million tons 31.4 Million tons

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Recommendations to Reduce Traffic & Increase Throughput

• Use larger capacity vehicles to increase throughput of every load / unload cycle

• Use larger capacity shovels to reduce loading time

• Consider replacing contract routes, such as ESM2, BCM and AKT with fewer and larger SECL vehicles

• Consider revisions in road layout by reducing the number of intersections

• Examine more scenarios to improve mine strategy

Scenario Development in Mine Traffic

Input Tables for:

1. Truck numbers for each route2. Load and Unload time of trucks3. Differing speeds4. Differing Truck capacities

Input data can be fed directly froma Excel spreadsheet into the KusmundaModel to examine different scenarios

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Safety with Mine Planning – future scope

• Vehicle fuel consumption rates in FlexSim model

• Truck break downs and repair

• Tire replacement based on kilometers travelled

• Statistics on actual loads carried by trucks for each category – analysis of weight distributions

• Excel input interface for ease of use and create a Web Interface to run the Kusmunda model

• Integrate Kusmunda mine model with SECL data base

• Optimize the mine model using advanced capability in FlexSim called OptQuest

• Add special objects, such as Load zones, Intersections, 3d layout convertor to enable easy build of mine models

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