Use of integrated loader dumper over shovel dumper combination

1. Roshan Kumar Patel
M.Tech, Mining Engineering
Roll No. 16152015
Use of
“INTEGRATED
LOADER
DUMPER”
over
“SHOVEL
DUMPER
COMBINATION”
INDIAN INSTITUTE OF TECHNOLOGY(BHU), VARANASI

2. Model Interpretation
Integrated loader dumper machine is designed to perform both loading and hauling
operation where it loads the dump onto itself and then hauls it to dump-yard.

3. For showing cost benefit analysis of INTEGRATED LOADER DUMPER
over SHOVEL DUMPER COMBINATION , calculation is done by the
company XYZ:
of the numbers of dumper and shovels required per face per year to
complete the excavation
and
also the number of ILD required to complete the same task
Step 1
Step 2
Cost benefit analysis in complete life of mine

4. Assumptions for Calculation
Swell factor of coal = 1 (There is no increase in the
volume of rock mass after blasting)
Working days in a year = 300
Cost of fuel = 55 ₹/ ltr

5. CALCULATION OF NO OF
SHOVELS & DUMPERS REQUIRED
Actual struck capacity of dumper = struck capacity * swell factor = 60.1 * 1
= 60.1 m3
Solid bucket capacity of shovel = bucket capacity * bucket fill factor * swell factor
= 12 * 0.85 * 1 = 10.2 m3
Avg. working hours in a year = 300 * 18 = 5400 hours
No. of passes required to fill dumper = 60.1/10.2 = 5.89 (approx. 6)
Loading time of shovel = swing time * no of passes = 0.50 * 6 = 3.0 min

6. CALCULATION
 Hourly productivity of shovel = 60 * bucket capacity*bucket fill factor * no of passes
loading time of shovel
= 60 * 10.2* 6 / 3.0 = 1224 m3
Annual productivity of shovel = Hourly productivity in m3 * effective hours in a year * density
= 1224* 1800 * 1.67
= 3679344 tons
= 3.6793 MT
Hauling time of dumper (unloaded) = dump yard distance * 60 / speed
= 1.5* 60 /25 = 3.6 min

7. Cycle time of dumper = loading time + haul time (to & fro) + dumping time+ spotting time
= 3.0 + (4.5+3.6) + 2+ 2 = 15.1 min
No of dumper required in 1 cycle time = cycle time of dumper / loading time of shovel
= 15.1 / 3.0 = 5.01 (approx. 5)
Productivity of dumper = Annual productivity of shovel
no. of dumper required per shovel
= 3.6793/5 = 0.736 MT
CALCULATION

8. No. of shovel required = annual estimated rate of production per year
annual production by shovel in 1 year
= 25 MT / 3.6793 MT = 7 (approx.)
No. of dumpers required = annual estimated rate of production per year
annual production by dumper in 1 year
= 25 MT / 0.736 MT = 34 (approx.)
CALCULATION

9. Actual capacity of integrated dumper = bucket capacity * swell factor
= 78 * 1 = 78 m3
Bucket capacity of integrated shovel = bucket capacity * bucket fill factor * swell factor
= 8 * 0.85 * 1 = 6.8 m3
Average effective working hours = 300 * 18 = 5400 hours
No of times shovel load into integrated dumper = 78/6.8 = 12 (approx.)
CALCULATION

10. Loading time of shovel of ILD = No of times loaded * loading time + spotting time
= 12 * 0.5 + 1 = 7.0 min
 Hauling time of ILD = dump yard distance * 60 / speed
= 1.5* 60 /25 = 3.6 min
Cycle time of dumper = loading time + haul time (to & fro) + dumping time+ spotting time
= 7.0 + (4.5+3.6) + 2 + 1 = 18.1 min
CALCULATION

11. Hourly productivity of ILD = 60 * bucket capacity * no of passes
Cycle time of ILD
= 60* 6.8 *12 / 18.1 = 270.5 m3
Annual productivity of shovel = Hourly productivity in m3 * effective hours in a year * density
= 270.5 * 2700 * 1.67 = 1219684.5 tons
= 1.219684 MT
Total no of ILD required = annual estimated rate of production per year
annual production by ILD in 1 year
= 25 MT / 1.219684 MT = 20.49 (approx. 21)
CALCULATION

12. Cost Benefit Analysis
1. Capital Cost
Shovel Dumper Combination
Shovel Cost = 7 * 8 crore
= 56 crore ₹
Dumper Cost = 34* 3 crore
= 102 crore ₹
Total Cost = 158 crore ₹
Integrated loader dumper
Total ILD Cost = 21* 6.5 crore
= 136.5 crore ₹
BENEFIT : 21.5 CRORE ₹

13. Cost Benefit Analysis
2. Maintenance Analysis
Shovel Dumper Combination
Maintenance requirement is 1 hour (in each 250
working hours) for shovel & 1 hour (in each 250
working hours) for dumper.
Maintenance hours for shovel = 22 hours
Cost of maintenance for shovel= 22* 1200* 7
= 1,84,800 ₹
Maintenance hours for dumper = 22 hours
Cost of maintenance of dumper = 22 * 800* 34
= 5,98,400 ₹
Total Cost per year per face = 7,83,200 ₹
Integrated loader dumper
Maintenance requirement for ILD is 1 hour
(in each 100 working hours)
Maintenance hours for ILD = 54 hours
Cost of maintenance of ILD = 54* 1600*21
= 86,400 ₹* 21
= 18,14,400 ₹
Total cost = 18,14,400 ₹
LOSS : 10,31,200 * 25 years = 2,57,80,000 ₹

14. Cost Benefit Analysis
3. Fuel Consumption
Shovel Dumper Combination
For shovel: (30 litres/hour)
Total litres of fuel = 30*7*5400
= 1134000 litres
For dumper: (65 litres/hour)
Total litres of fuel = 65*5400 *34
= 11934000 litres
Total fuel = 13068000 litres
Integrated loader dumper
Fuel economy is 115 litres/hour
Total litres of fuel = 115 * 5400 * 21
= 13041000 litres
BENEFIT : 27000* 55 * 25 years = 3,71,25,000 ₹

15. Cost Benefit Analysis
4. Manpower Requirement
Shovel Dumper Combination
Manpower required = 7 (for shovel) +
34 (for dumper)
= 41
Salary = 7 * 45,000 * 12+ 34*40000*12
= 2,01,00,000 ₹
Integrated loader dumper
Manpower required = 12 (multi skilled)
Salary = 21* 55,000*12
=1,38,60,000 ₹
BENEFIT : 62,40,000* 25 years = 15,60,00,000 ₹

16. Capital = + 21,50,00,000 ₹
Maintenance = - 2,57,80,000 ₹
Fuel = + 3,71,25,000 ₹
Manpower = + 15,60,00,000 ₹
Total = 38,23,45,000 ₹
Total benefit

17. According to cost benefit analysis & model
interpretation, use of ILD is far beneficial than shovel
dumper combination in many aspects.
Conclusion