Singareni Collieries Page 1 of 18 OPEN PIT DESIGN AND SCHEDULING - INTRODUCTION Information Technology has changed the way we live. Mining is no exception. Mining information systems have emerged encompassing all aspects of mine planning. Real time analysis of data is now possible that helps the mine administration to function effectively. Software is now available that covers the entire gamut of mine functions. The Singareni Collieries is now ahead in utilizing the computerized mine planning and completed design & scheduling of an opencast project on long term planning module – Apollo of Minex software. FEATURES: Minex is an integrated modular software including Survey, deposit evaluation, mine planning and design, production scheduling and equipment simulation. The user has the flexibility to select modules as per requirement. Generation of Borehole database Generation of reliable Geomodel 3D visualization of seam horizons/faults Generation of Reserves Database Pit Optimisation Open Pit Design and Scheduling Design of Haul roads, Earth works and Spoil dumps Underground mine planning and scheduling Generation of Mine Reserves Database Production Scheduling by target or equipment Generation of Plans, Sections and reports
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Singareni Collieries Page 1 of 18
OPEN PIT DESIGN AND SCHEDULING -
INTRODUCTION
Information Technology has changed the way we live. Mining is no exception. Mining
information systems have emerged encompassing all aspects of mine planning. Real time
analysis of data is now possible that helps the mine administration to function effectively.
Software is now available that covers the entire gamut of mine functions.
The Singareni Collieries is now ahead in utilizing the computerized mine planning and
completed design & scheduling of an opencast project on long term planning module –
Apollo of Minex software.
FEATURES:
Minex is an integrated modular software including Survey, deposit evaluation, mine
planning and design, production scheduling and equipment simulation. The user has the
flexibility to select modules as per requirement.
Generation of Borehole database
Generation of reliable Geomodel
3D visualization of seam horizons/faults
Generation of Reserves Database
Pit Optimisation
Open Pit Design and Scheduling
Design of Haul roads, Earth works and Spoil dumps
Underground mine planning and scheduling
Generation of Mine Reserves Database
Production Scheduling by target or equipment
Generation of Plans, Sections and reports
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OPENPIT DESIGN
PIT BOUNDARY
Quarry surface limit is defined on the basis of quarry floor limits by considering the
final slope of 45 degrees from incrop and 150m depth of Bottom seam at highwall side.
By considering the geological model of Pit-A, the bottom seam and middle seam
model grids are merged with BOW (Base Of Weathering) surface at incrop side to generate
benches upto the pit boundary/surface quarry limit.
BENCH DESIGN
The bench design is followed as per bench elevation at 10m interval with 70º slope
and 6.4m berm. To generate the bench ‘crest’ and ‘toe’ at every 10m elevation, SQL
(Structured Query Language) programme is used. The bench grids formed in the pit are
restricted upto topography / floor of the bottom seam as per the requirement.
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FIG.1
FIG.2
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Final pit benches are restricted to the Bottom Seam floor and topography as shown
below:
FIG.3
STRIP DESIGN
13 no. of strips with ‘crest’ and ‘toe’ in strike direction at 40m interval with 70 degrees
of slope and strip berm of 6.4 mtrs are projected on each bench grid.
FIG.4
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BLOCKS FORMATION
The pit is divided into number of blocks using layout lines across the strips at 40m
interval. Each block is assigned a number to report the reserves.
FIG.5 BLOCK DESIGN
FIG.6
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FIG.7 SECTION SHOWING THE BENCHES, STRIPS AND BLOCKS
MINE RESERVES
Mine Reserves database is created with ‘Codes’ and ‘Layers’ validated and loaded.
Merge model is created for the Pit - A for the selected layers. Layer wise mine reserves of
the pit can be obtained as desired.
FIG.8
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FIG.9 TYPICAL MERGED MODEL
FIG.10
Detailed Pit Reserves generated for Pit/Bench/Strip/Block is given at Annexure-1.
Also generated the status report along with stripping ratios is shown at Annexure-2. By
studying the detailed report of Pit reserves block wise, it is easy to identify the blocks in the
designed pit for scheduling.
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PRODUCTION SCHEDULING
Scheduling is primarily aimed at sequencing mining operations in a pit/ multi strip/multi
bench for coal or other layers. Target scheduling option is selected for the purpose.
TARGET SCHEDULING: This is the suitable method of scheduling to obtain a particular
coal target over a time period and to generate stage plans. This macro scheduler finds
applications in feasibility studies and production of long-range mine plans.
Details of Target Scheduling:
The project is proposed to extract coal with 0.60M.T per annum as installed capacity.
Accordingly a suitable calendar is prepared for the project. For each scheduled block,
reserves are reported and extraction of the quarry is planned for each coal seam/waste at
every stage.
Exposed blocks at the end of 1st year, 3rd year, 5th and final years of Pit-A are converted
as exposed grids. In a grid format the pit status can be used for dump design and/or back fill
planning.
FIG.11 STAGE - AT THE END OF 1 YEAR
Reports are generated for the quantity of coal extracted and waste removed at each
stage {at the end of 1st year, 3rd year, 5th year and 6th(final) year}.
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HAUL ROAD DESIGN
Haul roads are designed at 6.25% gradient with a width of 20m on exposed
grids/triangles keeping batter slopes at 57 degrees cut and 36 degrees fill.
FIG.12 HAUL ROAD DESIGN
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SPOIL DUMP DESIGN
Proposed area of overburden dumping is digitized. Dump design is made for every
stage of the project keeping the dump deck height as 30m, dump slopes at 28 degrees
and berm width as 30 mtrs for allowing safe transport.
FIG.13 FINAL EXTERNAL DUMP OF PIT-A
TRUCK SIMULATION
Truck and Shovel simulation system simulates the movements of a vehicle through
a network of roads and ramps and estimates traveling time and truck fleet requirement. It
can calculate the truck productivity (bank volume per truck hour).
The input to the program is divided into data sets that define the characteristics of
segments of routes, vehicle acceleration and deceleration potential at various velocities,
and shovel operating parameters
The following parameters are considered for truck simulation at a particular stage
of excavation.
Shovel bucket cubic capacity 2.80
Truck load by weight 25.00
Swell factor 1.20
Insitu density 2.20
Results are: i) Truck cycle time (minutes) 14.98
ii) Est. Min truck fleet required 3.94 (say 4)
iii) Bank volume per truck hour 46
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FIG.14
2D PLANS OUTPUT
The scheduling output of a stage on 2D plan is visible as blocks as shown below.
FIG.15
DE-COALED AREA
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It is felt very difficult to get the 2D plans output as desired in the form of ‘crest’ and ‘toe’
lines shown below.
FIG.16 STAGE PLAN END THE END OF 1st YEAR
FIG.17 STAGE PLAN END THE END OF 3rd YEAR
However, to overcome the problem, the ‘scheduling output at a particular stage’ is
digitized using Vista functions.
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CONCLUSION
Mine planning, designing and scheduling of an open pit are now made the mining
system easy.
Saves time in preparing number of alternative pit designs and production schedules
with different design and schedule parameters. A best suitable pit design and production
schedule can be selected.
Quick reporting of reserves of each layer / bench / strip / block is possible.
Year/month/day wise reports can be generated for the extracted volume of OB and Coal at
the end of each schedule.
The authors felt the necessity of 2D plans output to be customized rather than the
tedious process of digitizing the position of quarry at every end of the schedule.
ACKNOWLEDGEMENT
The Authors are thankful to the Singareni Collieries management for providing the
necessary software, hardware and encouragement in achieving the desired outputs through
Minex Software at SCCL.
REFERENCES
‘Getting Started with Apollo Mine Design & Reserves’, ECS International Pty Ltd,
Surpac Minex Group, Australia.
Mark Kelly, Peter Alexander, Surpac Minex Group, Australia, “Training programmes on
Apollo and Orion modules of Minex Software at Singareni Collieries”.
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DETAILED REPORT OF MINE RESERVES DATABASE (PIT/BENCH/STRIP/BLOCK/LAYER WISE)
SCHEDULE REPORT OF OPENPIT-100 AT THE END OF 1st YEAR Schedule 20 runs to SAT 31-DEC-05 18:03==============================================================Schedule 20 Accumulation values.
2.80BUCKET FILL FACTOR 1.00BUCKET LOADS PER TRUCK 4.87
SAY 5.0SPOT TIME 0.50SHOVEL CYCLE TIME 0.67TRUCK LOAD TIME 3.80SHOVEL AVAILABILITY % 100.0SHOVEL HOURS PER DAY 24.0
TRUCK PARAMETERS---------------- TRUCK LOAD BY WEIGHT
25.0TRUCK CUBIC LOAD 13.64TRUCK LOAD TIME 3.80TRUCK DUMP TIME 0.50TRUCK HAUL AND RETURN TIME 10.68TRUCK CYCLE TIME (MINUTES) 14.98TRUCK AVAILABILITY % 100.0EST. MIN TRUCK FLEET REQUIRED 3.94
SAY 4BANK VOLUME PER TRUCK HOUR 46-------------------------------------------
TRUCK PRODUCTIVITY-------------------------------------------TRUCKS PRODUCTION PRODUCTION