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CHAPTER 1 INTRODUCTION 1.1 PROBLEM DEFINITION SHOVEL TRUCK HAULAGE Tarkwa Rocky Gold Mining Company is proposing to develop a new open pit mine. Overburden will initially be removed by scraper and is therefore not the subject of this problem. The remaining oxidised ore must be drilled, blasted and transported to a crusher dump point, where it will be dumped for a front-end-loader to rehandle into the crusher. The anticipated haul profile for the first five years is given in Table 1. Speed limit is 44 kmph. Table 1 Haul Profile from Mining Face to Crusher Haul Segment 1 2 3 4 5 6 7 Length (ft) 400 (122m) 1700 (518.2m) 800 (243.8m) 2800 (853.4m) 900 (274.3m) 1600 (487.7m) 300 (91m) 8500 (2610.4m) The ore material is quite hard and fragments badly upon blasting and therefore management has recommended the use of diesel powered hydraulic front shovels for the excavation. However, the best shovel (model) is to be investigated and selected. Since Tarkwa Rocky Gold Mine has got a long-standing relationship with Caterpillar, it intends to consider only Caterpillar shovels. They are considering two models of hydraulic shovels. Table 2 presents some details on the shovels and their specifications. Table 2 Shovel Data Model Bucket Capacity Operating Weight Flywheel Kilowatt Availability Economic Life (hr) Cycle Time (min) 5110 7.8 m3 120000kg (264500lbs) 447kw (600hp) 0.91 25000 0.43 5130 9.5m3 179000kg (390000 lbs.) 563kw (755hp) 0.92 40000 0.46 Rolling Resistance (%) 3 2 4 2.5 3 3.5 4 Grade (%) 0 8 3 8 8 -2 0 Remarks Pit Bottom

Crusher Approach

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The loose density of blasted ore = 2.2t/m3 (141.63 lb/ft3) Material swell = 20% Size range = Run-of-mine Climate = Tropical Altitude = 200m (656ft) Quantity of material to be hauled per year = 12000000 tonnes

The company is considering a selection of two types of rear dump trucks manufactured by Euclid: EUR50C (50 ton capacity), EUR100C (100 ton capacity) Table 3 presents data on each of these trucks. Table 3 Data on Trucks

Truck Type Manoeuvre and Dump time (min) Spot time (min) Availability Economic life (hr)

EUR100C 1.2 0.55 0.87 30000

EUR50C 1.0 0.45 0.87 30000

1. Determine the shovel model (size) and truck model (size) and the corresponding shovel and truck fleets that will be required to meet production target, taking into consideration both technical and economic factors. Make assumptions where necessary, justify your assumptions. Make use of the Terex Vehicle performance and retarder charts and speed factors. 2. Present your results in the form of a report Each member of a group should actively participate in the work. This will be ascertained during an oral defense at the end of the semester. Make use of all recommended textbooks and class notes. Consult lecturer for clarification when necessary. 1.2 OBJECTIVES OF PROJECT To determine the shovel model (size) and the truck model (size) and the corresponding shovel and truck fleets that will be required to meet production target, taking into consideration both technical and economic factors.

1.3 SCOPE OF WORK This project work is limited to the process involved in the selection of Model Trucks and caterpillar Shovels for the most economic and optimum production of Gold at Rocky Gold Mining Company, Tarkwa.

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CHAPTER TWO COMPARING ECONOMIC LIFE OF EACH SHOVELWITH THE ANTICIPATED HOURS OF THE MINE. Anticipated years of operation Number of days of working = 5 years = 304 days

(Taking into consideration 52 Sundays of not working plus 10days considered as holidays by management) Number of effective hours of working per day = 21 hours (One hour delays for each of the 3 shifts) Quantity of material to be hauled per year Quantity of material to be hauled per day = = 12000000 tonnes

=
=

39473.68 tonnes / day

Quantity of material to be hauled per hour

1879.70 t/hr

Number of hours the shovel would be put to work in a day Number of hours the shovel would be put to work in a year

= 20 hrs = 20 300 = 6000 hrs

Number of hours the shovel would be put to work in five years = 6000 5 = 30000 hrs

From our result above, it is clearly seen that it is not advisable to go in for the shovel model 5110 unless two of them is to be purchased since it has a lesser economic life hours (25000 hrs) than -anticipated. However, this may not warrant rejection since it may make it up for the other factors of much importance.

Please note: all remarks with symbol are assumptions.

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2.1 Considering Truck Model EUR 100C Travel Time Truck gradeability when loaded: Gradeability =

=
= 332.29 1bs/hp This lies between 300 380 1bs/hp 2.2 Travel Time Table 2.1 Travel Time When Loaded

Haul Seg. 1 2 3 4 5 6 7

Length in (ft). 400 (122m) 1700 (518.2m) 800 (243.8m) 2800 (853.4m) 900 (274.3m) 1600 (487.7m) 300 (91m)

RR (%) 3 2 4 2.5 3 3.5 4

GR (%) 0 8 3 8 8 -2 0

TR (%) 3 10 7 10.5 11 1.5 4

Max Vel. (Km/hr) 43 15 21 13 12 56 34

SF 0.43 1.00 1.00 1.00 1.00 0.89 0.44

Mean Vel. (Km/hr) 18.49 (5.14m/s) 15.00 (4.17m/s) 21.00 (5.83m/s) 13.00 (3.61m/s) 12.00 (3.33m/s) 44.00 (12.22m/s) 14.96 (4.16m/s) Total Time =

Time (sec) 23.74 124.27 41.82 236.40 82.37 39.91 21.88 570.39

Please Note: Mean Vel. Value for Haul Seg. 6 is originally, 49.84 km/hr (13.844m/s) but has been cut down to the speed limit 44km/hr as required.

5 4 3 1 2

6 7

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Some interpolations that were made: Haul Seg.6 =

Hence, the S.F for haul seg. 6 is 0.89.

Haul Seg.7 =

Hence, the S.F for haul seg. 7 is 0.44.

Truck gradeability when empty:

Gradeability =

=
This lies under 300 lb/hp Table 2.2 Travel Time When Empty

= 141.81 lb/hp

Haul Seg. 7 6 5 4 3 2 1

Length (ft) 300 (91m) 1600 (487.7m) 900 (274.3m) 2800 (853.4m) 800 (243.8m) 1700 (518.2m) 400 (122m)

RR (%) 4.0 3.5 3.0 2.5 4.0 2.0 3.0

GR (%) 0.0 2.0 -8.0 -8.0 -3.0 -8.0 0.0

TR (%) 4.0 5.5 -5.0 -5.5 1.0 -6.0 3.0

Max Vel. SF 55.0 55.0 59.0 59.0 55.0 59.0 55.0 0.44 1.00 0.81 0.96 0.80 0.91 0.70

Mean Vel. (Km/hr) 24.20 (6.72m/s) 44.00 (12.22m/s) 44.00 (12.22m/s) 44.00 (12.22m/s) 44.00 (12.22m/s) 44.00 (12.22m/s) 38.50 (10.69m/s) Total Time =

Time (sec) 13.54 39.91 22.45 69.84 19.95 42.41 11.41 219.51

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Total Time Travelled = 570.39 + 219.51 = 789.9 seconds = 13.17 minutes

2.3 Cycle Time with Shovel Model 5110 Cycle time = Spot & Load Time + Travel Time + Turn & Dump Time For The Spot & Load Time Pay Load of Truck (100c) = 100 ton = 200000 lbs Tonnage per pass = dipper volume x loose density x fill factor (Assumed to be 0.9)
= 7.8m3 x 2.2t/m3 x 0.9 = 15.44t = 34029.76 lbs NB 1tonne=2204Ibs

Number of passes, Pt = = 5.88 6 passes Actual payload of Truck = Number of passes x tonnage/pass = 6 x 15.44t = 92.64t

Spot time = 0.55 min > shovel cycle time = 0.43 min Spot and load time = NptIC + tS tlC = (6x 0.43) + 0.55 0.43 = 2.70 minutes Manoeuvre and Dump time = 1.2min Truck Cycle Time = Spot & load time + total truck travel time + manoeuver and dump time = 2.7 + 13.17 + 1.2 = 17.07 minutes
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Production per one Truck in Hour = Actual Load = Number of passes x tonnage per pass = 6 x 15.44 = 92.64t Production = = 276.78 t/hr 0.85 is assumed value for productivity factor. Number of Operating Trucks =

= = 6.79 Truck fleet =

= = 7.80 8 trucks Number of Shovel required, NL =

= = 1.07 Availability of shovel Number of shovels

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= 0.91 =

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= 1.1 1 shovel Check Maximum number of trucks to match shovel =

=
= 6.32 x 1.07 = 6.76 7 trucks

= 6.32

2.4 Cycle Time With Shovel Model 5130 Cycle Time = Spot and Load Time + Travel Time + Turn and Dump Time For The Spot and Load Time Spot time = 0.55min > Shovel Cycle Time = 0.46min Spot & Load Time = Nptlc + ts tlc Tonnage per pass = dipper volume x loose density x ( Assumed ) fill factor = 9.5m3 x 2.2t/m3 x 0.9 = 18.81t = 41457.24lbs = 100 tons = 200,000 lbs = = 5.3 5 passes Actual Payload of truck = 5 x 18.81 = 94.05 t = (5 x 0.46) + 0.55 0.46 = 2.39 minutes Manoeuvre and Dump Time = 1.2 min

NB 1tonne : 2204Ibs Payload of Truck

Number of Passes

Spot & Load Time

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Truck Cycle Time

= 2.39 + 13.17 + 1.2 = 16.76 minutes

Production per One Truck in an Hour =

= = 286.19 t/hr Number of operating trucks =

= = 6.57 Truck Fleet =

= = 7.55 8 Trucks Number of Shovels, NL =

= = 0.94 Availability of shovel Number of shovels = = 1.02 = 1 shovel

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= 0.92

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Check Maximum number of trucks to match shovel =

= 6.3

= 6.30 x 0.94 = 5.93 trucks = 6 trucks

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CHAPTER THREE

3.1 Considering Truck Model EUR 50C Gradeability of truck when loaded Gradeability =

= = 291.24 lbs/hp This falls below 300 lbs/hp

3.2 Travel Time Table 3.1 Travel Time When Loaded Haul Seg. 1 2 3 4 5 6 7 Length (ft) 400 (122m) 1700 (518.2m) 800 (243.8m) 2800 (853.4m) 900 (274.3m) 1600 (487.7m) 300 (91m) RR (%) 3.0 2.0 4.0 2.5 3.0 3.5 4.0 GR (%) 0.0 8.0 3.0 8.0 8.0 -2.0 0 TR (%) 3.0 10.0 7.0 10.5 11.0 1.5 4.0 Max Vel. 55.00 15.50 22.00 15.00 15.00 55.00 37.00 SF 0.51 1.00 1.00 1.00 1.00 0.91 0.70 Mean Vel. (km/hr) 28.05 (7.79m/s) 15.00 (4.17 m/s) 22.00 (6.11 m/s) 15.00 (4.17 m/s) 15.00 (4.17 m/s) 44.00 (12.22 m/s) 25.90 (7.19 m/s) Total Time = Time (sec) 15.66 124.27 39.90 204.65 65.78 39.91 12.66 502.83

Please Note; The original Mean Vel. for haul seg. 6 is 50.05km/hr (13.90m/s) but has been cut to 44km/hr which is the speed limit required. Some interpolations that were made: Haul seg. 6 =

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Travel Time When Empty Gradeability of truck when empty:

Gradeability

= = 126.77 lbs/hp This also falls below 300 lbs/hp Table 3.2 Travel Time When Empty Haul Seg. 7 6 5 4 3 2 1 Length (ft) 300 (91m) 1600 (487.7m) 900 (274.3m) 2800 (853.4m) 800 (243.8m) 1700 (518.2m) 400 (122m) RR (%) 4.0 3.5 3.0 2.5 4.0 2.0 3.0 GR (%) 0.0 2.0 -8.0 -8.0 -3.0 -8.0 0.0 TR (%) 4.0 5.5 -5.0 -5.5 1.0 -6.0 3.0 Max Vel. SF 54.00 54.00 58.00 58.00 54.00 58.00 54.00 0.45 1.00 0.81 0.96 0.80 0.91 0.70 Mean Vel. (km/hr) 24.3 (6.75 m/s) 44.00 (12.22 m/s) 44.00 (12.22 m/s) 44.00 (12.22 m/s) 43.20 (12.00 m/s) 44.00 (12.22 m/s) 37.80 (10.50 m/s) Total Time = Time (sec) 13.48 39.91 22.45 69.83 20.32 42.41 11.62 220.02

Please Note; The original Mean Vel. of haul segments; 6, 5, 4 and 2 are 54.0km/hr (15.00m/s), 46 .98km/hr (13.05m/s), 55.68km/hr (15.47m/s) and 52.78km/hr (14.66m/s) respectively but have been reduced to 44km/hr which is the speed limit. Some of the interpolations made: S.F of haul seg 7 =

Total Travel Time

= 502.83 + 220.02 = 722.85 seconds = 12.04 minutes

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3.3 Cycle Time with Shovel Model 5110 Cycle Time For The Spot and Load time Payload of Truck (50c) = 50 ton = 100,000 lbs = dipper volume x loose density x (Assumed) fill factor = 7.8m3 x 2.2t/m3 x 0.9 = 15.44 t = 34029.76 lbs Pt = = 2.94 = 3 passes Actual Payload of Truck = 3 x 15.44 t = 46.32 t = Spot & Load Time + Travel Time + Turn & dump Time

Tonnage per pass

Number of Pass,

Spot Time = 0.45 min > shovel cycle Time = 0.43 min Spot and Load Time = Nptlc + ts - tlc = (3x0.43) + 0.45 0.43 = 1.31 min

Manoeuvre and Dump Time = 1.0 minutes Truck Cycle Time = 1.31 + 12.04 + 1.0 = 14.35 minutes

Production Per One Truck in an Hour =

= 0.85is the assumed productivity factor

= 164.62 t/hr

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Number of Operating Trucks =

= = 11.41 Truck Fleet =

= = 13.11 13 trucks

Number of shovels required, NL=

= =1.04 Availability of shovel Number of shovels = 0.91 = = 1.14 1 shovel Check Maximum number of trucks to match shovel =

= = 10.95 = 10.95 x 1.04 = 11.39 trucks 11trucks

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3.4 Cycle Time with Shovel Model 5130 Cycle Time = Spot and load Time + Travel Time + Turn and Dump Time The Spot and Load Time Spot Time Spot and Load Time Payload of Truck (50 c) = 0.45mins Shovel Cycle Time = 0.46 min. = Nptlc = 50 ton = 100,000 lbs = dipper volume x loose density x (Assumed) fill factor = 9.5m3 x 2.2t/m3 x 0.9 = 18.81 t = 41457.24 lbs Pt = = 2.41 2 passes

Tonnage per pass

Number of Passes

Actual Payload of Truck = 2 x 18.81 t = 37.62 t Spot and Load Time = 2 0.46 = 0.92 minutes

Manoeuvre and Dump Time = 1.0 mins Truck Cycle Time = 0.92 + 12.04 + 1.0 = 13.96 minutes

Production Per one Truck in an Hour =

= = 137.44 t/hr

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Number of Operating Trucks

= = 13.68

Truck Fleet

=
= 15.72 16 trucks Number of Shovel required, NL =

= = 0.90 Availability of shovel Number of shovels = 0.92 = = 0.98 1 shovel Check Maximum number of trucks to match shovel =

= 15.17

= 15.17 x 0.98 = 14.87 trucks = 15 trucks

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CHAPTER FOUR 4.1 Observations Table 4.1.1 Data on Shovel Model 5110 Bucket Capacity 7.8m 3 Operating Weight 120000kg (264500 lbs) Flywheel Kilowatt 447KW (600 hp) Availability 0.91 Economic life (hr) 25000 Cycle Time (min) 0.43

5130 9.5m3 179000kg (390000 lbs) 563KW (755hp) 0.92 40000 0.46

Table 4.1.2 Data on Trucks Truck Type Manoeuvre and Dump time Spot time (min) Availability Economic life (hr)

EUR 100C 1.2 0.55 0.87 30000

EUR 50C 1.0 0.45 0.87 30000

It is observed from table 4.1.2 that the Economic Life of Shovel Model 5130 (40000hr) is slightly above the anticipated years of operation (30000hr); while that for Shovel Model 5110 (25000) is less than the anticipated years of operation of Tarkwa Rocky Gold Mining Company.

Shovel Model 5130 again has a high Bucket Capacity and Flywheel Kilowatt than that for Shovel Model 5110.

From Table 4.1.2, we realized that both Truck Model EUR100C and EUR50C have the same Economic Life of 30000hr which matches with the anticipated years of operation. Shovel Model 5110 is not suitable for the problem in question due to its limitation in capacity and economic life.

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Table 4.1.3 Calculated result on Truck EUR 100C Type of Shovel Number of passes Tonnage per hour Number of Shovels Model 5110 6 15.44 1 Model 5130 5 18.81 1

Number of truck to Shovel 7 6

Table 4.1.4 Calculated result on Truck EUR 50C Type of Shovel Number of passes Tonnage per hour Model 5110 3 164.62 Model 5130 2 137.44

Number of shovels 1 1

Number of truck to shovel 11 15

It is also observed that both Shovels satisfy the recommendation that three to six (3 to 6) passes should fill truck except for Shovel Model 5110 when matched with Truck Model EUR100C.

From Table 4.1.3 and Table 4.1.4, Truck Model EUR100C is observed to check well with Shovel Model 5130 and Truck Model EUR50C is observed to check well with Shovel Model 5130 respectively.

Table 4.1.5 Comparing EUR100C & 5130 with EUR50C & 5110 Number of Passes Tonnage per Hour (t/hr) Number of Trucks Number of trucks to Shovel 6 Shovel Capacity And Economic Life 9.5m3 40,000hrs 9.5m3 40,000hrs

Selection Factors

EUR100C with 5130 EUR50C with 5130

287.05

137.44

16

15

From Table 4.1.5, it can be observed that considering the various selection factors considered Shovel Model 5130 offers the highest hourly tonnage matched with Truck Model EUR100C with a lower truck fleet (8 trucks) and this also checks well. Since both trucks and shovels have the same shovel capacity, same number of shovels, the same dipper volumes, then we consider the number of trucks for economic reasons.

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4.2

Conclusion

Based on the above observation, Shovel Model 5130 and Truck Model EUR100C have been selected since this match gives; Higher tonnage rate per hour Reduced logistic trouble (less truck fleet)

4.3 Recommendations Berms and escape lanes should be provided to improved safety. Traffic signs should be postal for velocity limits stops and intersection warnings. To avoid road damage, appropriate drainage ditches should be constructed, a curve, the necessary super elevation should be constructed to counteract the effect of centrifugal forces.

FIG 4.1 A Picture of a truck loading under a shovel

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References
Cummins A. & Given I. (1973): SME Mining Engineering Handbook, Vol. 1. Port City Press, New York.

Temeng, V.A. (2010): Lecture Notes on Material Handling (Unpublished). University of Mines and Technology, Tarkwa.

Anon (2010) http://www.metric-conversions.org

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