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    Load & Haul - 3 - Cost Optimisation

    Uploaded by

    Benito Lionel Zobo
    The document discusses strategies for optimizing costs in surface mining operations. It addresses evaluating and optimizing variable costs per tonne by improving productivity, operator efficiency through training, managing excavator and truck payload, and maintaining haul roads. It also discusses managing fixed costs by optimizing asset utilization through maintenance management, condition monitoring, and workforce planning to maximize equipment uptime. The overall goal is to minimize costs per tonne by improving various operational efficiencies.

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    © All Rights Reserved
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    Load & Haul - 3 - Cost Optimisation

    Uploaded by

    Benito Lionel Zobo
    68 views38 pages
    The document discusses strategies for optimizing costs in surface mining operations. It addresses evaluating and optimizing variable costs per tonne by improving productivity, operator efficiency through training, managing excavator and truck payload, and maintaining haul roads. It also discusses managing fixed costs by optimizing asset utilization through maintenance management, condition monitoring, and workforce planning to maximize equipment uptime. The overall goal is to minimize costs per tonne by improving various operational efficiencies.

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    Mining Production Document

    Original Title

    Load & Haul - 3 -Cost optimisation

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    The document discusses strategies for optimizing costs in surface mining operations. It addresses evaluating and optimizing variable costs per tonne by improving productivity, operator efficiency through training, managing excavator and truck payload, and maintaining haul roads. It also discusses managing fixed costs by optimizing asset utilization through maintenance management, condition monitoring, and workforce planning to maximize equipment uptime. The overall goal is to minimize costs per tonne by improving various operational efficiencies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    68 views38 pages

    Load & Haul - 3 - Cost Optimisation

    Uploaded by

    Benito Lionel Zobo
    The document discusses strategies for optimizing costs in surface mining operations. It addresses evaluating and optimizing variable costs per tonne by improving productivity, operator efficiency through training, managing excavator and truck payload, and maintaining haul roads. It also discusses managing fixed costs by optimizing asset utilization through maintenance management, condition monitoring, and workforce planning to maximize equipment uptime. The overall goal is to minimize costs per tonne by improving various operational efficiencies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 38

    Services for surface mining

    Truck and Shovel in open pit mine:


    Equipment selection and fleet design

    Cost optimisation
    25th November 2014
    Cost optimisation

    What make up cost per tonne ?

    USD $ / Tonne

    Total (variable + fixed ) cost / production


    Cost optimisation

    Variable cost / Productivity


    USD $ / T or Bcm

    USD $ / Hour T / Hour

    « Same Cost/Hour more T /Hour »


    Productivty improvement
    Cost optimisation
    Site condition
    Bench height adapted to size of excavators
    Cost optimisation
    Bench height
    Cost optimisation
    Site condition
    working space: long face , no pocket mining
    Cost optimisation

    Operator efficiency

    Training :
    All along the year with trainer and
    simulators

    Continuous improvement on
    simulators to follow progress
    Cost optimisation
    load & haul cost :

    1/3 loading cost

    2/3 hauling cost


    Cost optimisation
    Excavator Productivity
    Fragmentation Drill & blast

    Energy spend in blasting is less energy in crushing


    Cost optimisation
    Excavator Productivity
    good match between bucket size & truck body capacity
    3 to 6 passes
    Cost optimisation
    Excavator Productivity
    Round number of bucket

    Blasted material with block


    Average fill factor : 70%
    Banck density : 2,7 t/m3
    Loose density : 2,0 t/m3
    Bucket size : 18 m3 25,2 t per bucket
    Number of pass 3,65
    Bucket size : 15,3 m3 21,7 t per bucket
    Number of passes 4,3
    trucks always over loaded or under loaded

    Adapted bucket size : 16,5 m3

    Loose density to be controled


    Cost optimisation
    Excavator Productivity
    Bucket capacity limited by payload
    no excessive wear protection
    Cost optimisation
    Excavator Productivity
    Good positionning & swell angle limited

    The excavator should be positioned so that The excavator should only have to turn 45
    when the bucket is full the stick is vertical degrees from where it is digging to the truck

    The side of the truck should be just underneath the


    boomstick hinge pin when the load is dumped
    Cost optimisation

    Job organisation

    - Traming from block to block


    ( daily planning, phasing )
    - Traming for blasting
    ( nber of blast per week , planning phasing )

    Front line supervision


    Cost optimisation
    Truck Productivity
    Haul road design

    Maximum grade 10%


    Cost optimisation
    Truck Productivity
    Haul road design
    Cost optimisation
    Truck Productivity
    Haul road design
    Cost optimisation
    Truck Productivity
    Rolling resistance
    Cost optimisation
    Truck Productivity
    Road maintenance :
    Drainage : no water stagnent
    Haul road start at the loading face and end at the dump point
    « pit floor management , dump floor management»

    Good road base and good road surface to limit rolling resistance

    « Good roads improve production, extend tire life and


    reduce overall operating costs »
    Cost optimisation
    Truck Productivity
    Road maintenance

    Road construction with


    strong sub base

    Poor pit flor management…


    Cost optimisation
    Truck productivity ( cycle time)
    To control Road status : RAC = Road analisys control

    Record of Graph
    structure constraint

    Help to see singular


    deterioration of the haul
    road
    Cost optimisation
    Truck Productivity

    Road maintenance & pit floor management & tire life :

    Approximately 80% of large tires fail before wear out

    Factors affecting tire life


    Cost optimisation
    Truck productivity ( pay load)

    truck body adapted to material to match with the loose density


    and the nominal payload

    « Every Tonne added is a tonne less payd or a $ more cost »


    Cost optimisation
    Truck productivity ( pay load)

    No carry back No excessive wear


    protection
    Cost optimisation
    Truck productivity ( pay load)

    No excessive wear
    protection
    Cost optimisation
    Truck productivity ( pay load)
    Why manage payload

    Maintain safety
    Achieve optimum component lives ( garantie issue)
    Minimize spillage

    Impact fuel consumption No excessive wear


    Tire life protection
    Cycle time
    Availability
    Cost optimisation
    MineEIA Sensitivity Analysis- -Hauling
    A 5%Change in Each of the Listed Factors Cause the Following %Reduction in Cost Per Ton

    Reduction in Cost Per Ton

    5% Factor 0% 1% 2% 3% 4% 5% 6% 7%

    Operator Ef f ic ienc y

    Cy c le Times

    Pay load

    Fuel Cons umption

    Maintenanc e and Repair

    Mec hanic al A v ailability


    Utiliz ation

    Mac hine Capital

    Mac hine Lif e

    Operator Wages

    Tires
    Lubric ants

    A pprox imate range of f inal results , bas ed on analy s es to date.

    Cos t parameters , inc luding f uel, may v ary greatly by loc ation and applic ation
    Cost optimisation

    Fixed cost / production

    Optimum use of asset


    Maximum hours available
    Maximum operational utilisation
    Cost optimisation

    Mine planning

    Quantities optimisation
    Trucks hours smoothed along the life of mine
    Push back
    Haul distances weighted
    Cost optimisation

    Dispatch system

    Usely one excavator is working with 4 to 8 trucks and on


    a mine there is more than 1 excavator.

    When an excavator is in maintenance the fleet of trucks


    is either in maintenance , parked , or dispatch through the
    other excavators.

    Up to 20 trucks in a single pit it can be done by a


    dispatcher looking at pit situation
    Cost optimisation

    Dispatch system

    When more than 20 trucks are running , dispatch programm


    can be used : modular, minestar…

    GPS infrastructure
    Mine modeling
    Equipment tracking & fleet management
    Cost optimisation
    Maximum hours available =
    Maintenance management
    Maintenance strategie
    1st principle of maintenance :

    Repair before failure


    Less cost & less downtime than after failure
    Cost optimisation
    Maintenance strategie 3 levels

    • Daily Maintenance
    PLANNED AS
    PER BOOKS • Scheduled maintenance
    • Component planned maintenance

    PLANNIFICATION • Component predictive


    OPTIMIZATION maintenance

    UNPLANNED • Corrective maint. + proactive maintenance


    EVENTS

    Objective minimize unplanned maintenance


    Cost optimisation
    Maintenance management
    Performance Metrics

    Mechanical availability

    MTBS ( Mean Time Between Failures )

    MTTR ( Mean Time to Repair )


    Cost optimisation
    Maintenance management

    Condition monitoring

    Track of the component conditions


    SOS = Schedule Oil Sampling
    VIMS alerts
    Vital information management system ( CATERPILLAR)
    Vtital health management system (KOMATSU )

    Repair history and data trends


    base of proactive maintenance
    Cost optimisation
    Maintenance management
    Fluid management
    Fuel contamination control & filtration
    Oil quality
    Extend component life, reduce maintenance frequency
    Cost optimisation
    Maintenance management

    Planning & Scheduling

    to minimize delay to react :


    Mechanic workforce
    Bay space
    Parts procurement & delivery
    Cost optimisation
    Maximum operational utilisation =
    Operation management

    Workforce management :
    ( absenteism , multiskill…)
    Operationnal delay management :
    ( shift change , meal break…)
    Production delay management :
    ( blasting time , dispatch , site organization )

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