MUCKPILE SHAPING FOR DRAGLINES AND DOZERS AT SURFACE COAL MINES
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1 MUCKPILE SHAPING FOR DRAGLINES AND DOZERS AT SURFACE COAL MINES 26 August 2015 Sedat Esen Specialist Technical Services Engineer, Orica Document reference: FRAGBLAST11
2 INTRODUCTION 3 CASE STUDY 1 MUCKPILE SHAPING FOR DRAGLINES 6 CASE STUDY 2 MUCKPILE SHAPING FOR DOZERS 16 CASE STUDY 3 MUCKPILE SHAPING FOR DOZERS 20 CONCLUSIONS 23 2
3 INTRODUCTION Challenges with open cut coal mining: Coal prices plunging over the last three years Reducing the cost of production: Reduce cost inputs or Improve productivity We are looking at improving productivity. Three case studies: One Dragline operation: Two dozer operations 3
4 INTRODUCTION IMPROVING PRODUCTIVITY Case study 1: Changing blast parameters for a dragline operation for muckpile shaping Increased cast; Reduced rehandle; Reduced the need for dozers to aid in pad preparation. Case study 2: Changing blast parameters for a dozer operation for muckpile shaping Increased cast; Increased centre of mass displacement; Suitable profile for dozer. Case study 3: Maximise the dozer usage over truck & shovel 4
5 INTRODUCTION ENABLING TECHNOLOGIES SHOTPlus5 blast design software Electronic Blasting System (i-kon II, uni tronic ) A software for muckpile shaping (DMC) 5
6 CASE STUDY 1 MUCKPILE SHAPING FOR DRAGLINES Aim: improve the productivity of the main digging equipment. Project scope: Establish a good QA/QC process; Improved muckpile profile (optimum height of ~28m) for reducing rehandle and improving advance along strip; Increased cast percentage; Identify the coal loss and implement methods to reduce coal loss; and Implement changes to the drill and blast process with a continuous improvement imperative. 6
7 CASE STUDY 1 BLAST DESIGN PARAMETERS Hole diameter : 251mm; Burden : 7.5m; Spacing : 14m; Blasthole angle : 15 degrees; Hole depths : 30-45m; and Full strip fired. Weathered interbedded sandstone overlying sandstone/siltstone layers. 7
8 CASE STUDY 1 MODELLING MUCKPILE PROFILES DMC was calibrated using the base case (Measured cast: 23.1%) 8
9 CASE STUDY 1 MODELLING MUCKPILE PROFILES Burden (m) Base Case Case 1 Case 2 Case 3 Case 4 Row Row Row Row Row Row Row Row Row Average Burden(m) Spacing (m) Powder Factor (kg/m 3 )
10 CASE STUDY 1 MODELLING MUCKPILE PROFILES Case 1 was decided for implementation. Base case 10
11 CASE STUDY 1 MODELLING MUCKPILE PROFILES Key changes with Case 1: Blast pattern, bulk product choices, electronic blasting (timing) Pre QA/QC process Base Case Actual Case 1 Spacing (m) Powder Factor (kg/m 3 ) Initiation System Non-electric Electronic Electronic Bulk product Mostly Fortan TM Coal 12 Mostly Fortan TM Coal 12 Mix of Fortan TM Coal 12 and Aquacharge TM Coal Actual Cast (%) Modelled cast %:
12 CASE STUDY 1 RESULTS 4% increase in cast; Improved muckpile profile that reduced rehandle significantly (from 45% to 30%); Dragline productivity bcm/h was similar; Improved dragline rate of advance (two weeks ahead of schedule). 12
13 CASE STUDY 1 MODELLING FOR THE DRAGLINE ENTRY SIDES OF THE STRIP Site asked for a profile that looks like a ramp (ten degrees, 100mx35m) at the end of the strip. Dragline entry 13
14 CASE STUDY 1 MODELLING FOR THE DRAGLINE ENTRY SIDES OF THE STRIP Three cases: Case 1: Stand-up timing; Case 2: Stand-up timing and 5m air deck; and Case 3: Stand-up timing and 10m air deck. Base case 14
15 CASE STUDY 1 MODELLING FOR THE DRAGLINE ENTRY SIDES OF THE STRIP First half of the ramp area: 10m air deck and stand-up timing. The rest: 5m air deck and stand-up timing. Site was happy with the result: reduced dozer work, less downtime for dragline Dragline access 15
16 CASE STUDY 1 MODELLING FOR THE DRAGLINE ENTRY MIDDLE OF THE STRIP Similar approach. Modelling and electronic blasting timing were essential to the delivery. Dragline access 16
17 CASE STUDY 2 MUCKPILE SHAPING FOR DOZERS 100% dozer operation; Strip width: 50m Strip length: m Hole diameter: 229mm Hole angle: 20 degree Average hole length: 17m 7 rows Design powder factor: 0.33 kg/m 3 Spacing: 10m Bulk product: ANFO and Fortan Coal 11 (10-40%) 17
18 CASE STUDY 2 Key requirement: Cost reduction through increased cast % at design powder factor improved dozer muckpile profile for better dozer performance Project scope: Baselining of the non-electric blasts Trial and data collection process for electronic (UT600) blasts Report all data collected 18
19 CASE STUDY 2 RESULTS 19
20 CASE STUDY 2 KEY FINDINGS Muckpile profile was key to making the dozer push more effective. Uni tronic 600 Electronic Blasting System was essential to achieve the required results. 20
21 CASE STUDY 3 MUCKPILE SHAPING FOR DOZERS 25% of the overburden is blasted. Prior to the project, blasting was carried out for truck and shovel. Site asked if we can design the blasts for their dozers to reduce the total mining cost. Project scope: At the absence of the muckpile profile, we started using a calibrated DMC model for a similar operation in the same coal basin. Pre-blast and post-blast surveys; TOC identification; Design service; Baseline hole diameter: 165mm, hole length: 17m. 21
22 CASE STUDY 3 RESULTS Measured cast %:
23 CASE STUDY 3 RESULTS Base Case (Calibrated) Hole diameter (mm) Face angle Hole angle Cast (%) Simulation Simulation Simulation
24 CASE STUDY 3 RESULTS Cast percentage: % using 165mm drills Centre of mass movement: m Excellent fragmentation Good dozing productivity (operator feedback) Site happy with the cost reduction program. 24
25 CONCLUSIONS Reduction in the total cost of mining with the help of productivity improvements; Improved understanding of the post-blast muckpile profile; Muckpile profiles are unique to each site; Blast Movement Modelling; Electronic blasting systems are providing great flexibility with the timing required in any muckpile shaping project. 25
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