Rohit Pandey 1 1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012 Page | 1 Optimization of Load Per Trip of a Rear Discharge Dumper at Quarry S-E Block July 10 2011 Project Report of Summer Internship 2011 at TATA STEEL (West Bokaro Division) : Rohit Pandey
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Optimization of Load Per Trip of a Rear Discharge Dumper
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Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
Page
| 1
Optimization of Load Per Trip of a Rear Discharge
Dumper at Quarry S-E Block
July 10
2011 Project Report of Summer Internship 2011 at TATA STEEL (West Bokaro Division)
: Rohit Pandey
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
Page
| 2
Acknowledgement:
Myself, Rohit Pandey currently pursuing B.E. in Mining Engineering at Bengal Engineering and Science
University, Shibpur am most thankful to TATA STEEL for giving me the opportunity to complete my
summer internship project here at West Bokaro Division. I would like to thank Professor Suranjan Sinha,
HOD Department of Mining engineering, BESUS and all of my faculty members for guiding me properly
over the duration of my course. Special thanks to Mr. Sunil Kesarwani, my Project Guide; Mr. N. K. Gupta
(Chief Q-SE Block) my Project Mentor for guiding me to the insights of the project given to me. Thanks to
Capt. Salil Mohan for helping us with all our needs, Mr. B. Dinesh for helping me around the mines during
the shifts, to Mr. Subhankar Bose for helping me get all possible data required for the project, and to all who
have helped me in completing my project, and specially to all my fellow summer interns for making this
Summer Internship Program memorable.
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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| 3
CONTENTS:
Sl. No TOPIC PAGE NUMBER
1.0 Introduction to WBD 4
2.0 Location of West Bokaro 5
3.0 Scope of Work 6
4.0 Time Line 6
5.0 Understanding Shift Operations 7
6.0 Dumper Specifications and Policy 7
7.0 Increase of mine revenues 8
8.0 What may go wrong 8
9.0 Effect of load on tires 9
9.1 Tire damage analysis 9
9.2 Overloading of Tires 11
10.0 Factors relating load carried by dumper to tires 12
10.1 TKPH 12
10.2 Inflation pressure of the tires 17
10.2.1 Current status of tires in the mines 17
11.0 Optimization of Load capacity 20
12.0 Volumetric analyisis of dump body 22
13.0 Diesel Consumption Analysis 23
14.0 Speed Analysis 26
14.1 Speed during Out Pit Haul 26
14.2 Speed during In Pit Haul 27
15.0 Recommendation 28
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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1.0 Introduction to West Bokaro Division, Tata Steel:
West Bokaro (WB) came into existence in 1948, as an independent coal company, managed by M/S
Anderson Wright under the managing agency system. Tata Steel acquired the Company in 1956 to meet its
requirement of metallurgical grade coal for Iron making. Subsequently, in 1976, WB was made a Division of
Tata Steel. In 1974, when coal mines were nationalized, WB was exempted as it produced coal only for
captive consumption of the Steel Works. The coal industry in India is highly regulated with only few private
players allowed to produce coal only for captive use (in steel, cement and power industry). India has very
low reserves of coking coal. Indian coals in general are not suitable for steel making being high in
incombustible matter (Ash-25-38%) and also difficult to wash for reducing Ash. The first Washery of the
country was set up in WB. The current Washeries are designed to reduce Ash from 36% to 17% at a yield of
38%. Any further reduction in Ash was considered uneconomical because of significant drop in yield. (5%
drop for 1% drop in Ash). Though Ash can be reduced by improving process & application of technology,
Rank of coal which is result of „Metamorphosis‟ cannot be changed. Hence a large quantity of coking coal is
imported for blending with Indian coal to make it suitable for iron making. The business objective of WB
Division is to produce clean coal at optimum cost for captive use in the steel plant of Tata Steel at
Jamshedpur. The strategy is to reduce Ash with minimum loss of yield so that quality of coal improves and
yet the cost is beneficial vis-a vis imported coal.
The primary product of WB is the metallurgical grade coal (also called CC), for Coke Ovens, which converts
coal into coke for use in the Blast Furnaces. The type of coal deposit in WB is that of medium grade
metallurgical coal containing a very high percentage of Ash. Tata Steel has developed stamp charged
technology for using the coal from WB after blending it with imported coal. The coal after mining is washed
in the coal beneficiation plants to lower down the ash content from an average of 36% to 13%. Nowhere in
world the coal is beneficiated from 36% to 13% and in this regard the coal beneficiation process at WB is
unique. This is a highly commendable achievement especially in view of the fact that Indian coal comes
under the category of “difficult to wash coal”.
In order to improve the productivity of the Blast Furnaces, it is beneficial to lower down the Ash of CC.
However, with every 1% drop in Ash of CC the yield drops by 4-5% resulting in lower volume of CC and
thereby increasing the cost of production of CC. Every year Ash was reduced from 17% to 16% and this year
Ash has been further reduced to 13% at a very short notice from the customer. There was an extreme
Fig 1: Mining Processes in use at Q-SE Block
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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exigency to increase the productivity of blast furnaces in view of imminent shutdown of G-BF and recurring
problem of F-BF. The division responded to the demand of the customer immediately by reducing the Ash
from 15% to 13% level in 24 hours. The process is being stabilized and there is a continuous improvement in
yield even while reducing Ash. The delivery mechanism to steel plant at Jamshedpur is mainly through rail.
2.0 Location of West Bokaro:
Owner - H.M. Nerurkar (MD TATA Steel)
Location - West Bokaro is located about 200 km NW of Jamshedpur in Hazaribagh district. It is about
35 km SW of Hazaribagh town and 26 km NE of Ramgarh town.
Latitude - 23°46'41"N
Longitude - 85°33'6"E
Geographically, it is located west of Lugu Hill. It can be accessed via road from the town of Ramgarh. There
are several other coal mines, owned by M/s Central coal Fields Ltd around West Bokaro. The rain-fed
Bokaro River flows through the property. Total area of the leasehold is 4300 acres and contain an estimated
mine area reserves of about 180 million tonnes of Coal. The loading station at Chainpur is situated 4km to
the South.
Geology: Correlation of various coal seams was done on the basis of geological observations and available
data from boreholes and quarry sections. The Gondwanas of the Coalfiel doverlying unconformably the
Archeans are represented by the Lower Gondwanas - Talchirs, Kharharbaris, Barakars, Barren Measures,
Raniganjs, Panchets and the Upper Gondwanas -Mahadevas. About thirteen regionally persistent coal seams
have been established in the area. The thick coal seams of the Coalfield are seam-V (7m on average) and
seam-X (10m on average). The coal seams belong to low moisture, low volatile, medium to high caking
bituminous group. The Grade varies from Grade-II to IIIB. Seam VI and VII are the best quality coal seams
which attain Grade-I quality in Ghato and Pundi areas and seam-X also have Grade-I quality in Kuju area.
The total reserves for the Coalfield have been estimated to be 2500 million tonne up to 600m depth
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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3.0 Scope of work:
The project aims to selecting an optimum load that a RD is subjected to carry per trip, based on the Cost
benefit model.
4.0 Time line of work:
Week 1 • Visit to the mine.
• Familiarizing with the basic mine unit operations
Week 2 • Understanding the scope of work
• Identification of basic parameters of the project
Week 3 • Tire analysis
Week 4
• Tire analysis continued
• Volumetric analysis
• Review of work
Week 5 • Troubleshooting of work done
Week 6 • Fuel Consumption and TPMS Data Analysis
Week 7 • Speed Analysis
Week 8 • Recommendations
• Submission of project report
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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5.0 Understanding shift operations:
The 1st 3 days (17
th may – 19
th of may) I went to the SEB in the First Shift . In these 3 days I studied the
basic Shift operations which are as follows:
1. Development Job
2. Drilling & Blasting
3. Loading & Hauling
4. Dump yard and CHP
6.0 Dumper Specifications and Policy:
The dumper being used is of CATERPILLAR make, model 777D (dual slope)
The rated payload is 95 T (Caterpillar specifications)
The proper working of the dumper is subjected to the 10/10/20 policy by Caterpillar according to
which;
‘Only 10% of all loads carried by the dumper should exceed (110%) 1.1 times the rated payload and
No load should exceed (120%) 1.2 times the rated payload.’
Optimum Load Zone
Fig 2:- Graphical representation of 10-10-20 policy
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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7.0 Increase of Mine Revenues:
Any increase of payload per trip will decrease the cost of handling of Over burden/cubic meter.
This will reduce the mining costs and will better the breakeven ratio, resulting in the increase in the mine
revenues.
Above given is the general relation between the payload per trip to the cost of removal of OB.
8.0 What may go wrong:
Trying to increase the payload per trip of the dumper, a number of problems may arise. They are:
Tire Failure
Suspension failure
Excessive Spillage
Machine frame damage
Increase of Cycle time
Decrease of Speed
Increase of Fuel consumption with low efficiency, etc.
We try to assess the some real time factors in the following advancements.
Fig 3:- Payload of RD vs Cost of OB removal
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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9.0 Effect of Load on Tires:
It is evident that the load carried by the tires directly affects the life of the tires and its performance.
Any overload situation will cause major damages to the tire which may or may not be reused. Following
damages might occur in any overload situation:
Ply separation
Cord and Bead damage
Uneven wear
Cut and Impact damages
Excessive heat generation
Centre wear out
So it is necessary to study the effects of load and other relative parameters on the tire.
9.1 Tire damages in FY 11:
We analyze the number of tires discarded due to different reasons in FY 1, which shows that the number of
tire cuts beyond point of repair has drastically increased. A further study in this will in the current months
will give us a proper picture.
Fig 4:- Tire failures in FY11
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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Now, we try to analyze the number of tires cut/damaged beyond point of repair in FY11 and the current
months, where there has been a significant increase of load per trip carried by the Dumpers.
So we see that in APR‟11 and MAY‟11, where there was an increase of average load per trip carried by the
RD, the number of tire cuts went up by 1100%.
05
101520253035
Ap
r/1
0
May
/10
Jun
/10
Jul/
10
Au
g/1
0
Sep
/10
Oct
/10
No
v/1
0
Dec
/10
Jan
/11
Feb
/11
Mar
/11
Ap
r/1
1
May
/11
No
of
Tire
fai
lure
Radial Tires
Rainy Season
Fig 5:- Number of tire failures in FY11
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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9.2 Overloading affects life of tires:
The effect of overload adversely affects the life of tires. Any overload can enhance the rate of damages
caused to the tire and hence bring about a significant decrease in the expected run hours of the tire. Adjoining
is given a comparison of the overload percent to the change in tire life to the corresponding overload.
Here we see that
overloading the tire reduces the
expected run hours of the tires and
proper loading will ensure that the
expected run hours are met with.
But the case may arise in
overloading, that there might be an
increase of Maintenance costs, but
simultaneously, the excess payload
that the dumper carries may
increase revenues in terms on cost
of OB removal / mt3
Fig 6:- Change in tire life vs Load on tire
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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| 12
10.0 Factors relating load carried by the dumper to tires:
There are a few factors which relates load carried by the dumper with the tire. They are:
Ton Kilometre Per Hour Rating (tkph factor of a tire): The tkph factor should be less than the rated
factor to ensure proper conditions.
Inflation Pressure of the tire: The pressure to which the tire is inflated is in direct relation with its
load bearing capacity.
Gradient of the haul road: Uphill climb always adds excess weight on to the rear tires, and down hill
haul in case of in pit dumping does the same to the front tires.
Shift of c.g. at turns in the haul road: There is a slight shift of cg due to turning at haul roads although
proper super elevation helps in reducing the effect.
10.1 Tons Kilometer Per Hour (TKPH):
Heavy duty haulage causes heat development in tires. As the tires have limited resistance to heat, detoriation
of the tyre may begin at a very early stage of operation due to excess heat development. Hence, it is
necessary to determine the amount of work that will keep the tires within a safe range to avoid overheating
when the vehicle is operated under the given conditions and within the safe range can be determined as
below:
TKPH = mean tyre load * average work day speed
Mean tyre load = (empty tyre load + loaded tyre load)/2
Average work day speed = 𝑅𝑜𝑢𝑛𝑑 𝑡𝑟𝑖𝑝 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 ∗ 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑦𝑐𝑙𝑒𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑜𝑓 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑑𝑎𝑦
There must be a limit, both in load and haul distance, whereby the TKPH formulae will no longer apply,
Tires loaded at 20% above then rated capacity or used in haul roads of more than 25km will not qualify for TKPH calculation.
The following graph gives us an idea of the separation damages that can be caused due to increased
temperatures caused by high TKPH values.
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012
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Let us consider a sample tkph calculation with real time data:
Dumper is RD 115
Dated April 21, 2011
Round trip distance = 3.81 *2 kms = 7.62 kms.
No of cycles= 17
Hours of operation = 05:32 hrs. to 14:54 hrs. = 9.5 hrs.
Average work day speed = (7.62*17)/9.5 = 13.635. .
Front Tires Rear Tires
Load on tire when the dumper is empty = 11.88 T
Load on tire when the dumper is loaded = 5.496 T
So, mean tire load = (11.88+25.496)/2 = 18.688 T
So, TKPH = 18.688 * 13.635
TKPH = 254.81
Load on tire when the dumper is empty = 12.06 T
Load on tire when the dumper is loaded = 25.85 T
So, mean tire load = (12.06 + 25.85)/2 = 18.955 T
So, TKPH = 18.955 * 13.635
TKPH = 258.45
(safe operational TKPH values = 423)
TKPH Value calculation Neglecting Idle time, assuming the dumper was in operation for the whole time
continuously
Fig 7:- % Separation damage at different temperatures
Rohit Pandey1
1 B.E. Mining Engineering, Bengal Engineering and Science University, Shibpur 2008-2012