open pit design

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


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.


FIG.1

FIG.2


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


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


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


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.


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}.


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


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


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


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.


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”.


DETAILED REPORT OF MINE RESERVES DATABASE (PIT/BENCH/STRIP/BLOCK/LAYER WISE)

Seam Bench Volume Volume Tonnes Waste Coal Coal

--------------------------------(Cu.m)----(Cu.m)----------------Pit A-------WEATH 2 32343WEATH 3 339153WEATH 4 1281332WEATH 5 2889683MS 5 38842 4199 6508BS 5 10154 1479 2293WEATH 6 3316494MS 6 464363 21350 33093BS 6 54944 11827 18331WEATH 7 1917337MS 7 1418174 58957 91383BS 7 168046 32860 50933WEATH 8 278993MS 8 2574173 98257 152299BS 8 281292 54761 84880MS 9 2480027 110828 171783BS 9 295613 70419 109149MS 10 2124540 132633 205581BS 10 281074 69416 107595MS 11 1787487 147243 228227BS 11 277216 63373 98229MS 12 1464424 160777 249205BS 12 283244 61701 95637MS 13 1156298 155777 241454BS 13 294825 64532 100025MS 14 877736 141768 219740BS 14 282969 68224 105747MS 15 614988 137683 213408BS 15 261715 63863 98987MS 16 369829 134534 208527BS 16 243592 58933 91346MS 17 160637 110064 170600BS 17 226981 62352 96645MS 18 40438 43235 67014BS 18 190281 57734 89488MS 19 8387 1972 3056BS 19 77560 43474 67385BS 20 6878 11825 18329

--------- --------- ---------TOTAL 28872068 2256047 3496877

-----------------------------SUMMARY Volume Volume

Tonnes Waste Coal Coal

Pit A-------WEATH 10055337MS 15580355 1459275 2261877BS 3236385 796773 1234999

--------- --------- ---------28872068 2256047 3496877

ANNEXURE - 1


STATUS REPORT OF MINE RESERVES DATABASE (PIT/BENCH/STRIP/BLOCK/LAYER WISE)

Pit Ben Str Blk Layer % % % % %UWed%LWed %Reh VolumeNo. No. No. No. ID. Expo Surf Prem Mine*%R.D.*%Ash*EffS/R* Tonnage*Thick--- --- --- --- ----- ---- ---- ---- ---- ----- ---- ------ -----100 2 1 1 WEATH 100 0 0 0 439 4.4100 2 1 2 WEATH 100 0 0 0 5765 3.0100 2 1 3 WEATH 100 0 0 0 3830 1.8100 2 1 4 WEATH 100 0 0 0 19 0.1100 2 2 1 WEATH 100 0 0 0 8598 3.4

CONTD…------------------------------------------------------------------------

INTENTIONALLY LEFT THE BLANK SPACE------------------------------------------------------------------------100 19 12 10*MSC 0 0 0 0* 1.55* * 8.4* 667* 1.1100 19 12 10 BSIB 0 0 0 0 2184 3.6100 19 12 10*BSC 0 0 0 0* 1.55* * 8.4* 2291* 1.6100 19 13 3*BSC 0 0 0 0* 1.55* * 8.4* 118* 0.4100 19 13 4 BSIB 0 0 0 0 663 1.7100 19 13 4*BSC 0 0 0 0* 1.55* * 8.3* 6097* 2.8100 19 13 5 BSIB 0 0 0 0 988 2.0100 19 13 5*BSC 0 0 0 0* 1.55* * 8.3* 6311* 3.7100 19 13 6 BSIB 0 0 0 0 2353 3.3100 19 13 6*BSC 0 0 0 0* 1.55* * 8.3* 5978* 3.6100 19 13 7 BSIB 0 0 0 0 6651 6.5100 19 13 7*BSC 0 0 0 0* 1.55* * 8.3* 4127* 2.3100 19 13 8 BSIB 0 0 0 0 3559 6.9100 19 13 8*BSC 0 0 0 0* 1.55* * 8.3* 1904* 2.5100 19 13 9 MSOB 0 0 0 0 1626 9.4100 19 13 9*MSC 0 0 0 0* 1.55* * 8.3* 866* 2.1100 19 13 9 BSIB 0 0 0 0 1498 4.6100 19 13 9*BSC 0 0 0 0* 1.55* * 8.3* 1582* 3.0100 20 9 14 BSIB 0 0 0 0 180 1.8100 20 9 14*BSC 0 0 0 0* 1.55* * 8.3* 1949* 2.1100 20 9 15 BSIB 0 0 0 0 2175 4.4100 20 9 15*BSC 0 0 0 0* 1.55* * 8.3* 3455* 1.7100 20 10 12 BSIB 0 0 0 0 1745 3.0100 20 10 12*BSC 0 0 0 0* 1.55* * 8.3* 2734* 1.3100 20 10 13 BSIB 0 0 0 0 408 1.4100 20 10 13*BSC 0 0 0 0* 1.55* * 8.3* 3693* 2.3100 20 10 14 BSIB 0 0 0 0 1432 3.6100 20 10 14*BSC 0 0 0 0* 1.55* * 8.3* 2543* 3.6100 20 10 15 BSIB 0 0 0 0 359 8.2100 20 10 15*BSC 0 0 0 0* 1.55* * 8.3* 69* 1.1100 20 11 11 BSIB 0 0 0 0 223 2.2100 20 11 11*BSC 0 0 0 0* 1.55* * 8.3* 750* 1.0100 20 12 9*BSC 0 0 0 0* 1.55* * 8.3* 50* 0.3100 20 12 10 BSIB 0 0 0 0 343 3.1100 20 12 10*BSC 0 0 0 0* 1.55* * 8.3* 1510* 1.4100 20 13 4*BSC 0 0 0 0* 1.55* * 8.3* 8* 0.1100 20 13 6*BSC 0 0 0 0* 1.55* * 8.3* 31* 0.1100 20 13 7*BSC 0 0 0 0* 1.55* * 8.3* 252* 0.4100 20 13 8*BSC 0 0 0 0* 1.55* * 8.3* 448* 1.4100 20 13 9 BSIB 0 0 0 0 11 0.1100 20 13 9*BSC 0 0 0 0* 1.55* * 8.3* 835* 2.7Total WASTE Volume(Cu.m) 28872066 Tonnage 63518572Total COAL Volume(Cu.m) 2256046 Tonnage 3496875

ANNEXURE - 2


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.

Waste Coal/Ore Waste Coal/OreVolume+ Tonnage Volume+ Tonnage

(Rehandle) (ROM)(Rehandle) (ROM)==============================================================SAT 01-JAN-05 WEATH 546200 546200TOTALS 546200 546200TUE 01-FEB-05 WEATH 493336 1039536TOTALS 493336 1039536TUE 01-MAR-05 WEATH 539663 1579199

MSOB 98 98MSC 717 717BSIB 4623 4623BSC 2097 2097

TOTALS 544383 2815 1583920 2815FRI 01-APR-05 WEATH 528578 2107777TOTALS 528578 2112497 2815SUN 01-MAY-05 WEATH 533340 2641117

MSC 186 903BSIB 8716 13339BSC 6249 8346

TOTALS 542056 6435 2654553 9250WED 01-JUN-05 WEATH 488812 3129929

MSOB 20260 20358MSC 8419 9322BSIB 11986 25325BSC 3232 11578

TOTALS 521058 11651 3175611 20901FRI 01-JUL-05 WEATH 504615 3634543

MSOB 27851 48209BSIB 7470 32795BSC 9709 21287

TOTALS 539937 9709 3715547 30610MON 01-AUG-05 WEATH 179353 3813896

MSOB 252589 300798MSC 32176 41499BSIB 80009 112804BSC 20905 42192

TOTALS 511951 53081 4227498 83691THU 01-SEP-05 WEATH 158188 3972084

MSOB 177557 478356MSC 41519 83017BSIB 137889 250693BSC 43639 85831

TOTALS 473634 85157 4701133 168849SAT 01-OCT-05 WEATH 510335 4482420

MSOB 7549 485905MSC 10134 93152BSIB 19993 270687BSC 2772 88604

TOTALS 537878 12907 5239011 181755TUE 01-NOV-05 WEATH 295805 4778225

MSOB 131534 617439MSC 33785 126936BSIB 64581 335268BSC 23038 111642

TOTALS 491921 56823 5730931 238578THU 01-DEC-05 WEATH 352281 5130505

MSOB 60312 677751MSC 25924 152860BSIB 89739 425007BSC 35294 146936

TOTALS 502332 61218 6233263 299796

Annexure - 3


TRUCK FLEET REQUIREMENT

------------------------------------------- MATERIAL PARAMETERS-------------------SWELL FACTOR 1.20INSITU DENSITY 2.200

SHOVEL PARAMETERS----------------- BUCKET CUBIC CAPACITY

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

(BANK VOL/HR) (BANK -------------------------------------------

1 46 10932 91 21853 137 32784 179 4306

-------------------------------------------

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Annexure - 4

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open pit design