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Optimizing Powered Haulage Investment in Surface Coal Applications
Optimizing Powered Haulage Investment in Surface Coal Applications
All mines require efficient equipment to move material in a cost and time
effective manner. As this pertains to all mines the focus today will be
with surface coal operations and the following key points:
1. Horsepower - The effect it has with fuel consumption and requirements
for coal haul profiles vs. other applications
2. Gear Ratio - Analyze the effect gear ratio has on performance and how
this should be interpreted for achieving best operation in the field
3. Cost per Tonne – Discuss in regards to what the driving factors are and
how the current coal market allows for greater mine flexibility
Mine Operating Costs
What percentage of mining operation costs are
attributed to open pit mining equipment?
Fuel consumption is always the primary cost with haulage and loading fleets
Horsepower & Fuel Consumption
Fuel consumption is directly proportional to horsepower
20V4000 640
100% Load Factor Fuel Consumption (L/hr)
617
16V4000 QSK 78
522 547
490
QSK 60
455
Only four major engine types for >240tonne electric drive mining trucks
Haul Profile Definition
Segment Length
200m @ 0%
Segment Grade
Rolling Resistance
200m @ 0%
Speed Limits
2500m @ -10%
Typical Downhill Loaded Haul
350m @ 0%
500m @ 10%
1600m @ 0%
Gear Ratio Effects
37.33:1 ratio
Greater top end
300k lb-f vs. 350k lb-f speed – 64kph
43.7:1 ratio
Greater low-end
“breakout” torque
Lower top end
speed – 54kph
54kph (34mph) vs.
64kph (40mph)
0 5 10 15 20 25 30 35 40 45
mph Speed
Cost per Ton Drivers
Payload
The most effective way at lowering a cost per tonne is to increase
payload
More material hauled = more $$
Horsepower
Cycle Times
Fuel consumption
GVW
Plays important role in cycle times, fuel consumption and is
influenced by horsepower
This study is not a comparison of any two OEM’s equipment, thus
GVW has been excluded
Old Belief still holds true?
To Recap:
1. Primary mining operating cost is fuel
2. Higher horsepower equals higher potential fuel consumption
3. Coal haul profiles are generally flat and long
4. Low gear ratio has higher top end speed than high gear ratio
5. High payload is essential to low cost per ton
16V4000
QSK 78
QSK 60 .175
L/hp
+350hp = 2kph!
100
3000hp
3000hp
80 3650hp
3650hp
Propulsion Separation Point 5.4 kph
60 Propulsion
3650 37.3:1Separation Point 5.4 kph
40
20
0
0.0 10.0 20.0 30.0 40.0 50.0 60.0
Speed (kph)
Low end torque needed for high RR at face and dump sites
43.7:1 better suited for soft underfoot conditions, less often under loaded intentionally due to
struggling to pull away from the face when fully loaded (greater TPH!!!)
World wide tire shortage causing many mines to restrict speeds and TKPH, thus taking away
advantage of lower gear ratio’s top end capability
43.7:1 more efficient than 37:33 on grade thus creates less heat and requires less cooling
Coal Market Trends
+95%
+40%
+7%
Coal demand has caused prices to outpace supply both domestically and
internationally over the past five years
2007 was second highest year of U.S. production, only to 2006 production
Haul Simulation Study
75 coal haul profiles from three separate operations were simulated with increased RR at
the face as seen at each operation
Typical mine speed limit of 50kph (31mph)
Fuel Consumption
Tonne per Hour
Tonne per Litre within 1-2%, yet the 3650hp with higher gear ratio has a 9% greater
revenue/profitability
Cost per tonne is significant but production holds greater weight
Conclusion
Proper horsepower, gear ratio and payload matching for mining applications still
holds true today
The world-wide coal market is spawning new concepts in the industry; deeper
pits for coal, higher hp fleets, ultra class trucks
Coal is the dominant energy source for at least the next two decades
The haul simulation study performed was on actual haul profiles, not generic
To fully optimize production and profitability for a coal mine the following key
components of a powered haulage fleet must be taken into account:
1. High Payload – Ultra Class payload for maximum production
capability
2. High Horsepower – Technologically advanced, efficient engines for
greater speed on grade as coal mines expand from surging prices
3. High Gear Ratio – Need low end torque for soft conditions,
sufficient cooling for deeper pits, and operation top end speed not
an issue due to speed limits and tire preservation
Thank you…