Presentation made on application of advanced transport system forsustainability of opencast mining

1. ADOPTION OF NEW TECHNOLOGIES IN OPENCAST MINING
FOR SUSTAINABLE GROWTH
Presentation prepared for 3rd MineTech, 6th March, 2020
Organized by Indian Chamber of Commerce
Presented by S.K.BAG
Director,
Indian Mine Planners & Consultants
IMPCON

2. IMPCON
Indian Mine Planners & Consultants (IMPCON) was established
in 2007 with the prime objective of guiding for total mining solution
in Mine Planning for the Mine Entrepreneurs of Government, Public
Sectors and Private Sector bodies engaged in the field of Coal
mining, Metal and non-Metal mining.
IMPCON is an ISO 9001 COMPANY & an accreditated
envirornment consultant organisation of QCI – NABET
IMPCON had been empanelled as Technical Consultants of
Coal India Limited, the world’s largest coal producing company
in the world.

3. ISO CERTIFICATE OF IMPCON

5. MODE OF IN-PIT TRANSPORT IN OPENCAST MINE
CONVENTIONALLY IN OPENCAST COAL MINES DUMPER
TRANSPORT IS PREFERRED DUE TO THE FLEXIBILITY OF DUMPER
SYSTEM.
BUT DUMPER TRANSPOT BECOMES INEFFICIENT AND COSTLY WITH
THE INCREASE OF TRANSPORT DISTANCE.
DIESEL PRICE AND SPARES FOR DUMPERS BEING MOSTLY
IMPORTED, ADDS TO COST DUE TO EXCHANGE RATE VARIATION.
TO COPE UP WITH HIGHER PRODUCTION AND TO REDUCE
TRANSPORT COST, ALTERNATIVE TECHNOLOGIES BECOMES
INEVITABLE FOR SUSTAINIBILITY AND ALSO TO REDUCE
POLLUTION IN MINES.

6. WINNING
10%
LOADING
31% TRANSPORT
59%
WINNING
22%
LOADING
18%
TRANSPORT
60%
INVESTMENT COST OPERATING COST
6

8. Description % of Total
Ownership 25
Major Repairs 12
Tyres 4
Undercarriage 4
Sub Total 20
Fuel & Oil (Energy cost) – Energy cost for conveyor is cheaper by
more than 25% over fuel & oil cost for dumper – For “OB” the savings
on transport shall be quite substantial.
38
Servicing 4
Overheads & Misc 6
Repair Parts 4
Repair Labour 2
Buckets, bowls and blades 1
Sub Total 55
8

9. (‘OB’ removal cost is higher than coal)

10. Estimated comparison of cost per ton between conveyor & haul truck

11. 1. ENERGY REQUIREMENT:
FOR DUMPER TRANSPORT:
-ONLY 40% ENERGY IS CONSUMED FOR THE TRANSPORT OF PAYLOAD
-60% IS CONSUMED FOR DEAD-WEIGHT OF VEHICLE & RETURN TRIP
-TO LIFT 100 TE PAYLOAD BY 10 M TRUCK NEEDS 2 LITERS DIESEL
-TO MOVE 100 TE PAYLOAD HORIZONTALLY OVER 1 KM TRUCK NEEDS
ABOUT 8 LITERS DIESEL
FOR CONVEYOR TRANSPORT:
-80% ENERGY IS USED FOR PAYLOAD TRANSMISSION
-TO LIFT 100 TE PAYLOAD BY 10 M CONVEYOR NEEDS 3 KWH ENERGY
-TO MOVE 100 TE PAYLOAD HORIZONTALLY OVER 1 KM CONVEYOR
NEEDS 12 KWH ENERGY
S.K.Bag

12. 2. SERVICE WEIGHT TO PAYLOAD:
i) FOR 85 TE DUMPER:
PAYLOAD = 77 TE
WEIGHT OF DUMPER = 58 TE
SERVICE WEIGHT: 2 x 58 + 77 TE = 193 TE
( DUMPER TO BE MOVED FULL IN UP & EMPTY IN DOWN )
For dumper:
RELATION OF SERVICE WEIGHT TO PAYLOAD :- 193/77 = 2.51
ii) FOR CONVEYOR, 1800 MM WIDE ( TROUGH 40 DEG) :
MATERIAL WEIGHT PER METER (Sp.Gr. 1.6 TE/CU.M) = 620 KG
MASS OF ROTATING & MOVING PARTS / METER = 154 KG
TOTAL MASS IN OPERATION PER METER = 774 KG
For conveyor:
RELATION OF TOTAL MASS TO PAYLOAD :- 774/620 = 1.2
S.K.Bag

13. 3. COST OF WEAR AND SPARE PARTS:
FOR DUMPERS:
TIRES : YEARLY COST IN RELATION TO INVESTMENT COST
- APPROXIMATELY 5 – 10%
FOR CONVEYORS:
BELTS : YEARLY COST IN RELATION TO INVESTMENT COST
- APPROXIMATELY 1 - 2%
4. OPERATORS WAGE:
DUMPERS HAVE APPROX. THREE TO FOUR TIMES HIGHER COST
S.K.Bag

14. ADVANCED MINING TECHNOLOGIES IN
OPENCAST MINING TO REDUCE TRANSPORT
COST

15. FROM PIT BOTTOM TO SURFACE

16. IN-PIT CRUSHING AND TRANSPORT BY
CONVENTIOAL CONVEYOR

17. SHORTER ROUTE BY CONVEYOR
LONGER ROUTE BY DUMPER
TWO IN-PIT GYRATORY CRUSHERS
17S.K.Bag

18. CASE STUDY – COMPARISON OF COST BETWEEN DUMPER &
CONVEYOR TRANSPORT

19. DUMPER
TRANSPORT CONVEYOR
TRANSPORT

22. APPLICATION OF SANDWICH HIGH ANGLE
CONVEYOR

23. HIGH ANGLE CONVEYOR CLEARING MUCK FROM UNDERGROUND TUNNEL FOR METRO RAILWAY AT PARIS – CAN
BE USED FOR UNDERGROUND MINING IN INDIA AS AN ALTERNATIVE TO SKIP

24. IN-PIT CRUSHING AND HIGH ANGLE CONVEYOR ALONG SIDE WALL FROM PIT BOTTOM TO SURFACE FOR
TRANSPORT OF PAY MINERAL (FOR DEEP OPENCAST CAST MINE)
SAVE HUGE COST AND REDUCE POLLUTION (UNDER IMPLEMENTATION IN INDIA)
DSI HIGH ANGLE
CONVEYOR

25. APPLICATION OF HIGH ANGLE CONVEYOR ALONG SIDE WALL FROM PIT BOTTOM IN DEEP OPENCAST CAST
DSI HIGH ANGLE
CONVEYOR

26. CASE STUDY OF APPLICATION OF HIGH ANGLE CONVEYOR AT SOUTH AFRICA

27. PROFILE OF HIGH ANGLE CONVEYOR ALONG SIDE WALL

29. MODEL CASE STUDY
HIGH ANGLE CONVEYOR AT KATHARA
OPENCAST MINE (HIGHLY DEEPING SEAM)
(CENTRAL COAL FIELDS LTD)

30. KATHARA OPENCAST MINE

31. KATHARA OPENCAST MINE

32. PROPOSED ROUTE OF HIGH ANGLE CONVEYOR AND SURFACE CONVEYOR TO WASHERY
OPENCAST MINE

33. HIGH ANGLE CONVEYOR/SURFACE CONVEYOR ROUTE SHOWN IN YELLOW
AND PRESENT DUMPER ROUTE SHOWN BY RED
ROUTE LENGTH FOR DUMPER – 2500 M
ROUTE LENGTH FOR HAC – 620 M

34. ECONOMIC ANALYSIS AND COMPARISON BETWEEN TWO SYSTEMS FOR KATHARA

37. ADVANCED LONG DISTANCE TRANSPORT
TECHNOLOGY (OUT OF PIT)

38. ROPECON TECHNOLOGY

39. ROPECON FOR LONG TRANSPORT - OUT OF PIT TO DESTINATION
(SHORTEST ROUTE, MINIMUM LAND, MINIMUM POWER, MINIMUM SOUND, ECO-FRIENDLY)

40. IMPCON ROPECON TRANSPORT

46. LARCODEMS
ADVANCED COAL BENEFICIATION TECHNOLOGY
INTRODUCED BY BRITISH COAL

51. S.K.Bag
IMPCON
S.K.BAG