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Singareni Collieries Page 1 of 18

OPEN PIT DESIGN AND SCHEDULING -

I.T SOLUTION FOR LONGTERM MINE PLANNING

D.L.R. Prasad1, P. Srinivas

2, B. Sambasivarao

3, *D. Gopinath

4

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

1. Chief General Manager, 2. Dy. Supdtg. Er, 3. Sr. Survey Officer,

The Singareni Collieries Company Limited (A government Company), Kothagudem, Andhra Pradesh., INDIA

* 4. Under Manager Now working at Surpac Minex, Hyderabad, INDIA

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A project is taken up at Singareni Collieries to design a pit, spoil dump and production

scheduling using Apollo & Orion modules of MINEX software, to get the desired pit design

and stage wise plans for preparation of feasibility report.

PROJECT DETAILS

The Pit - A is designed upto 150 m depth of Bottom Seam. There are two down

throw and one up throw faults in the property.

SUMMARISED DATA

Sl.

No

Description

1.0 INSITU RESERVES M.T 3.497

1.1 MINEABLE RESERVES M.T -----

1.2 TOTAL OVERBURDEN M.Cu.m 28.872

1.3 AVG.STIPPING RATIO Cu.m/T 8.3

2.0 BOREHOLE DENSITY No./Sq.Km 35.58

3.1 MAXIMUM STRIKE LENGTH ALONG

SURFACE

Meters 933

3.2 MAXIMUM STRIKE LENGTH ALONG FLOOR Meters 7184.1 MAXIMUM WIDTH OF THE QUARRY ALONG

SURFACE

Meters 621

4.2 MAXIMUM WIDTH OF THE QUARRY ALONG

FLOOR

Meters 420

5.1 MINIMUM DEPTH OF THE QUARRY Meters 28.00

5.2 MAXIMUM DEPTH OF THE QUARRY Meters 150.0

6.1 FLOOR AREA OF QUARRY Ha. 21.45

6.2 AREA OF EXCAVATION ON SURFACE Ha. 45.15

7.0 AVERAGE GRADIENT OF THE SEAM 1 in 3.5

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8.0 DETAILS OF WORKABLE SECTIONS

PIT-ASECTION

MINIMUM MAXIMUM

- MIDDLE SEAM 4.65 8.53

PARTING 14.63 17.65

- BOTTOM SEAM 3.18 4.41

9.0 QUALITY

UHV(Kcal/kg) Grade

PIT A 4758 D

10.0 TECHNOLOGY SELECTED : SHOVEL-DUMPER COMBINATION

11.0 INSTALLED CAPACITY : 0.60 M.T per annum12.0 LIFE OF THE PROJECT : 6 YEARS

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 70 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.

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FIG.1

FIG.2

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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

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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

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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

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FIG.9 TYPICAL MERGED MODEL

FIG.10Detailed 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.

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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}.

Eg: Annexures-3.

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DETAILS OF COAL PRODUCTION & OVERBURDEN REMOVAL IN PIT- A

Cumulating

End of

the Year

Coal (MT) OB (M.cu.m) Str. Ratio

1 0.30 6.233 20.77

3 1.50 18.621 12.41

5 2.70 26.995 10.00

6(Final) 3.497 28.872 8.30

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

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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 (Annexure - 4).

The following parameters are considered for truck simulation at a particular stage of

excavation.

Shovel bucket cubic capacity 2.80

Truck load by weight 25.00Swell 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

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FIG.14

2D PLANS OUTPUT

The scheduling output of a stage on 2D plan is visible as blocks as shown below.

FIG.15

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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

INCROP

DIP

DE-COALED AREA

FIG.17 STAGE PLAN END THE END OF 3rd YEAR

How ever, to overcome the problem, the scheduling output at a particular stage is

digitized using Vista functions.

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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.

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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 32343

WEATH 3 339153

WEATH 4 1281332

WEATH 5 2889683

MS 5 38842 4199 6508

BS 5 10154 1479 2293

WEATH 6 3316494

MS 6 464363 21350 33093

BS 6 54944 11827 18331

WEATH 7 1917337

MS 7 1418174 58957 91383

BS 7 168046 32860 50933

WEATH 8 278993

MS 8 2574173 98257 152299

BS 8 281292 54761 84880

MS 9 2480027 110828 171783

BS 9 295613 70419 109149

MS 10 2124540 132633 205581

BS 10 281074 69416 107595

MS 11 1787487 147243 228227

BS 11 277216 63373 98229

MS 12 1464424 160777 249205

BS 12 283244 61701 95637

MS 13 1156298 155777 241454

BS 13 294825 64532 100025

MS 14 877736 141768 219740

BS 14 282969 68224 105747

MS 15 614988 137683 213408

BS 15 261715 63863 98987

MS 16 369829 134534 208527

BS 16 243592 58933 91346

MS 17 160637 110064 170600

BS 17 226981 62352 96645

MS 18 40438 43235 67014

BS 18 190281 57734 89488

MS 19 8387 1972 3056

BS 19 77560 43474 67385

BS 20 6878 11825 18329

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

TOTAL 28872068 2256047 3496877

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

SUMMARY Volume Volume Tonnes

Waste Coal Coal

Pit A

-------

WEATH 10055337

MS 15580355 1459275 2261877

BS 3236385 796773 1234999

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

28872068 2256047 3496877

ANNEXURE - 1

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

WISE)

Pit Ben Str Blk Layer % % % % %UWed%LWed %Reh Volume

No. 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 4.4

100 2 1 2 WEATH 100 0 0 0 5765 3.0

100 2 1 3 WEATH 100 0 0 0 3830 1.8

100 2 1 4 WEATH 100 0 0 0 19 0.1

100 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* 1.1

100 19 12 10 BSIB 0 0 0 0 2184 3.6

100 19 12 10*BSC 0 0 0 0* 1.55* * 8.4* 2291* 1.6

100 19 13 3*BSC 0 0 0 0* 1.55* * 8.4* 118* 0.4

100 19 13 4 BSIB 0 0 0 0 663 1.7

100 19 13 4*BSC 0 0 0 0* 1.55* * 8.3* 6097* 2.8

100 19 13 5 BSIB 0 0 0 0 988 2.0

100 19 13 5*BSC 0 0 0 0* 1.55* * 8.3* 6311* 3.7

100 19 13 6 BSIB 0 0 0 0 2353 3.3

100 19 13 6*BSC 0 0 0 0* 1.55* * 8.3* 5978* 3.6

100 19 13 7 BSIB 0 0 0 0 6651 6.5

100 19 13 7*BSC 0 0 0 0* 1.55* * 8.3* 4127* 2.3

100 19 13 8 BSIB 0 0 0 0 3559 6.9

100 19 13 8*BSC 0 0 0 0* 1.55* * 8.3* 1904* 2.5

100 19 13 9 MSOB 0 0 0 0 1626 9.4

100 19 13 9*MSC 0 0 0 0* 1.55* * 8.3* 866* 2.1

100 19 13 9 BSIB 0 0 0 0 1498 4.6

100 19 13 9*BSC 0 0 0 0* 1.55* * 8.3* 1582* 3.0

100 20 9 14 BSIB 0 0 0 0 180 1.8

100 20 9 14*BSC 0 0 0 0* 1.55* * 8.3* 1949* 2.1

100 20 9 15 BSIB 0 0 0 0 2175 4.4

100 20 9 15*BSC 0 0 0 0* 1.55* * 8.3* 3455* 1.7

100 20 10 12 BSIB 0 0 0 0 1745 3.0

100 20 10 12*BSC 0 0 0 0* 1.55* * 8.3* 2734* 1.3

100 20 10 13 BSIB 0 0 0 0 408 1.4

100 20 10 13*BSC 0 0 0 0* 1.55* * 8.3* 3693* 2.3

100 20 10 14 BSIB 0 0 0 0 1432 3.6

100 20 10 14*BSC 0 0 0 0* 1.55* * 8.3* 2543* 3.6

100 20 10 15 BSIB 0 0 0 0 359 8.2

100 20 10 15*BSC 0 0 0 0* 1.55* * 8.3* 69* 1.1

100 20 11 11 BSIB 0 0 0 0 223 2.2

100 20 11 11*BSC 0 0 0 0* 1.55* * 8.3* 750* 1.0

100 20 12 9*BSC 0 0 0 0* 1.55* * 8.3* 50* 0.3

100 20 12 10 BSIB 0 0 0 0 343 3.1

100 20 12 10*BSC 0 0 0 0* 1.55* * 8.3* 1510* 1.4

100 20 13 4*BSC 0 0 0 0* 1.55* * 8.3* 8* 0.1

100 20 13 6*BSC 0 0 0 0* 1.55* * 8.3* 31* 0.1

100 20 13 7*BSC 0 0 0 0* 1.55* * 8.3* 252* 0.4

100 20 13 8*BSC 0 0 0 0* 1.55* * 8.3* 448* 1.4

100 20 13 9 BSIB 0 0 0 0 11 0.1

100 20 13 9*BSC 0 0 0 0* 1.55* * 8.3* 835* 2.7

Total WASTE Volume(Cu.m) 28872066 Tonnage 63518572

Total COAL Volume(Cu.m) 2256046 Tonnage 3496875

ANNEXURE - 2

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SCHEDULE REPORT OF OPENPIT-100 AT THE END OF 1st YEARSchedule 20 runs to SAT 31-DEC-05 18:03

==============================================================

Schedule 20 Accumulation values.

Waste Coal/Ore Waste Coal/Ore

Volume+ Tonnage Volume+ Tonnage

(Rehandle) (ROM)(Rehandle) (ROM)

==============================================================

SAT 01-JAN-05 WEATH 546200 546200

TOTALS 546200 546200TUE 01-FEB-05 WEATH 493336 1039536

TOTALS 493336 1039536

TUE 01-MAR-05 WEATH 539663 1579199

MSOB 98 98

MSC 717 717

BSIB 4623 4623

BSC 2097 2097

TOTALS 544383 2815 1583920 2815

FRI 01-APR-05 WEATH 528578 2107777

TOTALS 528578 2112497 2815

SUN 01-MAY-05 WEATH 533340 2641117

MSC 186 903

BSIB 8716 13339

BSC 6249 8346

TOTALS 542056 6435 2654553 9250

WED 01-JUN-05 WEATH 488812 3129929MSOB 20260 20358

MSC 8419 9322

BSIB 11986 25325

BSC 3232 11578

TOTALS 521058 11651 3175611 20901

FRI 01-JUL-05 WEATH 504615 3634543

MSOB 27851 48209

BSIB 7470 32795

BSC 9709 21287

TOTALS 539937 9709 3715547 30610

MON 01-AUG-05 WEATH 179353 3813896

MSOB 252589 300798

MSC 32176 41499

BSIB 80009 112804

BSC 20905 42192

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

MSOB 177557 478356

MSC 41519 83017

BSIB 137889 250693

BSC 43639 85831

TOTALS 473634 85157 4701133 168849

SAT 01-OCT-05 WEATH 510335 4482420

MSOB 7549 485905

MSC 10134 93152

BSIB 19993 270687

BSC 2772 88604

TOTALS 537878 12907 5239011 181755

TUE 01-NOV-05 WEATH 295805 4778225

MSOB 131534 617439

MSC 33785 126936

BSIB 64581 335268BSC 23038 111642

TOTALS 491921 56823 5730931 238578

THU 01-DEC-05 WEATH 352281 5130505

MSOB 60312 677751

MSC 25924 152860

BSIB 89739 425007

BSC 35294 146936

TOTALS 502332 61218 6233263 299796

-

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TRUCK FLEET REQUIREMENT

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

MATERIAL PARAMETERS

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

SWELL FACTOR 1.20

INSITU DENSITY 2.200

SHOVEL PARAMETERS

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

BUCKET CUBIC CAPACITY 2.80

BUCKET FILL FACTOR 1.00

BUCKET LOADS PER TRUCK 4.87

SAY 5.0

SPOT TIME 0.50

SHOVEL CYCLE TIME 0.67

TRUCK LOAD TIME 3.80

SHOVEL AVAILABILITY % 100.0

SHOVEL HOURS PER DAY 24.0

TRUCK PARAMETERS

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

TRUCK LOAD BY WEIGHT 25.0

TRUCK CUBIC LOAD 13.64

TRUCK LOAD TIME 3.80

TRUCK DUMP TIME 0.50

TRUCK HAUL AND RETURN TIME 10.68

TRUCK CYCLE TIME (MINUTES) 14.98

TRUCK AVAILABILITY % 100.0

EST. MIN TRUCK FLEET REQUIRED 3.94

SAY 4

BANK VOLUME PER TRUCK HOUR 46-------------------------------------------

TRUCK PRODUCTIVITY

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

TRUCKS PRODUCTION PRODUCTION

(BANK VOL/HR) (BANK VOL/DAY)

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

1 46 1093

2 91 2185

3 137 3278

4 179 4306-------------------------------------------

*****

Annexure - 4

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