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The objective of this study is to provide an overview of the new aggregate plant at Shumaisi site, between Makah and Jeddah. Although, aggregates are relatively inexpensive at its source, the cost of transportation is often the major factor in determining the competitive cost to the consumer. The absence of natural aggregate at cost-effective transportation distances has prompted extensive use of manufactured aggregates. The extensive use of manufactured aggregates has required proper modification of characterization, design and construction practices. In addition, it has motivated studies to reduce energy consumption, to attain optimal crusher design and operation, and to minimize waste. Crushing operations can accommodate some adjustment to match the demand for each gradation.
Capital lay out cost daily production(m 3) working days(per year) per m 3 Cost of Production SR per day 14.35 SR 20.00 SR 5.65 SR
SR 15,000,000 3000 300 per year 43,050.00 SR 60,000.00 SR 16,950.00 SR 12,915,000 18,000,000 5,085,000
Selling Price SR Net Profit SR
Aggregate is the chief raw material used in Portland cement concrete and asphalt, which are universally used for construction and road paving purposes.These basic resources are essential for building roads, houses, schools and hospitals. Aggregate has an amazing variety of uses. More than 95 percent of asphalt pavement and more than 80 percent of a concrete sidewalk is aggregate.
There are three major considerations that are a prerequisite to opening a new aggregate plant:
Supply and demand in the local market area.
Daily an average of 18000 tons per day (11000 tons plus 7200 tons from johrana study) Is being supplied in local Makah market. Local demand and daily productions at johrana aggregate plants
Sr. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Company /Owner Musaad Almatrafy Masood Al Lakhyani Jamhaan Al Lakhyani Mohajer Al Khaleeg Co. Rio Company Mohammad Abdul Rehman Al Sewan Bin Zohefa Co. Saudi Crushing Co. Al Jazeera Co. Artec Co. Arrfa Co. Khuddrey Wahda Al Antajeen Al Gharmol Al Martan Mansoor Sawadi
Daily Production (tons) 1200 1200 900 1800 1200 2400 1200 1200
Remarks Plant in erection stage
Don,t sell material
Don,t sell material Don,t sell material Don,t sell material Don,t sell material Plant is stopped Don,t sell material
Total daily production
2) The type of deposit to be mined and the processes required to mine it. In makah we have only granitic deposits and for large scale production we have to install fixed plant. 3) Obtaining the permits necessary to operate the site. Permit for Shumaisi area is already in process and Eng. Abdul Manheim is working for it. Meanwhile sami rock is looking to occupy another area near Shumaisi outside Makahas soon as govt. starts licensing that area.
3. Plant Design There are many plant-engineering options to consider, when setting up an aggregates plant from scratch. Using quality components from the start often prevents problems later.eg market review. Market review To see what the potential market is. Some of the pieces of information from the market review are as follows: Information How much of each product can be sold. Total product specifications. Are all sales by customer truck, or should delivery services be offered? Selling price for all products. Competition in the market area. Market review 100 % 1/2”,1/4”,3/4”,3/8” both 20 to 26 SR/m3 In Shumaisi area Samirock plant will be the 2nd one.
1 2 3 4 5
The mineral characteristics also play an important part in the decision as to whether or not the property is suited for aggregate production. The mineral characteristics will have to be analyzed to determine whether we can produce the materials our market review calls for. These characteristics also help to define the type of processing equipment that can be used. Some of the material characteristics we checked for making the proper decisions are listed below: Material name. Material source (quarry or gravel pit). Bulk density Specific Gravity. Aggregate abrasive value Absorbtion Hardness. Compressive strength. Chemical composition used to determine abrasiveness of material (requires at least the following: Silica, iron oxide, aluminum and magnesium oxide.) Percent clay, dirt, etc. Moisture. Feed material top size. Feed material size distribution. Rhyolite quarry +/- 1.6----1.8 tons/m3 2.77 +/- 6----10 0.8% 6---7 150----250 N/mm2 average
average 0.8% 1000mm 10%>900mm
Type of plant The type of plant selected will generally depend on how long the reserves will last. Sami rock is suggesting for stationary plant.
Stationary plant: This type of plant is generally associated with quarried materials where the expected life of the quarry is more than 10 years. Some of the characteristics of this type of plant are as follows: • Requires substantial civil work. • Primary surge pile. • Bins feeding crushers. • Large stockpiles. • Complete plant automation. • Large clearances around equipment for servicing.
Truck and loadout systems.
• Concrete and steel structures. • Stationary conveyors. Other things using jaw crusher as follows: • Ease of replacing wear members. • Ease of setting adjustment to both compensate for wear and also product requirements. • Good production rate. • Easy Serviceability. • Easy Parts availability. • Ease of operation. Process flow The process flow is one of the most important parts in defining how your new aggregate plant is going to operate to make the required products as economically as possible. Along with selection of the proper crusher, the proper screens and feeders need to be made. Some of the information required to select the proper screen or feeder are listed below: • feed size. • Feed gradation. • TPH.
Process flow diagram of Shamaisi aggregate plant
The process flow starts with the plant feed material and ends when all of the products have been produced. Plant layout At this stage following factors would be considered . • • • • • surge-pile capacities stockpile capacities minimum clearances under conveyors minimum clearances around crushers and screens and how stockpiles are going to be maintained
In the past, aggregates plants were mechanical in nature, with plant operations such as crushing, screening and conveying functioning separately and manually. Over the past two decades, however, automation has provided a 2 to 10 time increase in productivity in many different aspects of an aggregate plant's operations. But one thing is certain: the process of making little rocks out of big ones has not changed. Automation and computer technology have simply provided the industry with the high-tech tools needed to make greater productivity possible. So the plant will be equipped with high level of latest instruments.
5. Drilling & BLASTING
Drilling is one of the critical elements in the drilling and blasting process. The drilling phase is the most expensive in the drilling and blasting portion of production, requiring a sizable investment and upkeep. The impact of improper drilling can be felt throughout the remainder of the production cycle, such as excavating and hauling, crushing, screening and so on. For maximum success it is essential that the mine or quarry carefully design its blasts to achieve the desired fragmentation results. These designs must be accurately implemented in the field. The blasts must be shot in a safe manner, with the area properly barricaded and all persons removed a safe distance away. Environmental affects such as ground vibration, airblast and fume production must also be controlled.
Basis for drilling & blasting a) Daily Production = 3000 M3
b) Bench Height c) Dia Of Hole
= 12m = 76mm
D YD IL INGC C L IONS AIL R L AL U AT d ily p u a rod ction = Item volum e spacing burden Dia of hole production/LM Total drilling LM drill rig capacity total no of drills average depth of hole total no of holes total no of holes/blast quantity produced/blast
E P OS C C AT N X L IVE AL UL IO
3,000 m 3 V lu a e 3,000 4 3 76 12 250 150 2 12 21 200 26,400 u its n m 3 m m m m m 3 m m no,s m no,s no,s m 3 C lcu tion a la /exp n tion la a
Item V lu a e u its n base charge 3.7 kg base charge length 1.1 m coulmn charge length 8.9 m coulmn charge wt./m 3.65 kgs coulmn charge wt. 32 kgs tot. wt. of exp/hole 36 kgs 132 m3 production/hole 0.274129 kgs/m3 specific charge
kem ulux/m 3 ANFO/m 3 total kem ulux total ANFO 0.0280303 0.2460985 84.090909 kgs 738.30 kgs
C lcu tion a la
D IL ING B AS ING C T C C AT R L L T OS AL UL ION
S.N 1 2 3 4
ITEM kemulux ANFO SANEL EL. Det DEMS
UNITS NO OF UNITS S.R /UNIT COST (SR) kgs 84 18 SR 1,512 m 738 10 SR 7,383 no,s 21 15 SR 315 no,s 5 10 SR 50 SR 9,260 SR 0.20 SR 600 SR 9,860 SR 3.29
total explosive cost Blasting services/ m3 services cost total blasting cost cost /m3
drilling cost/m SR 10.00 production/lm 11 m3 drilling cost/m3 SR 0.91 total drilling +blasting cost
Front-end loaders or hydraulic excavators will be used to scoop blasted material from the
quarry face and transfer it to a haul truck to begin the processing sequence. Excavators can further be used to pull loosely defined material directly from the quarry face.Dozers D-9 will assist the the loading process.
HEAVYEQUIPMENTS no of units
D ilyproduction(M3 a ) 3 0 ,0 0 m 3
# 1 2 3 4
Equipment Dozer D9 Loader Cat 966 Breaker 220 Dumper(28t)
Daily daily Required Capacity/trip working production production production or Bucket hours (m3/hour) (m3) 3000 3000 NA 3000 NA 3m3 NA 10 10 10 NA 10 150 150 NA 70 1500 1500 NA 700
cost ca lcula tion s
D ilyproduc a tion (M3 )
S. R NO Equipm nt e 1 DOZ D9 ER 2 LOADER 966 3 Breaker 220 4 DUMPER (28t)
No,sof units 2.0 2.0 2.0 4.3
Working hours @ Total Prod/hour 1 0 producti C t/H os r (M3 ) hrs /day on 300 150 10 3,000 100 150 10 3,000 90 20 10 200 100 70 10 3,000
total cos (S ) t R S 6,000 R S 2,000 R S 1,800 R S 4,286 R
C t/m os 3 S 2.00 R S 0.67 R S 9.00 R S 1.43 R
cost/m S 4.70 3=R
daily production(m3) S .NO R 1 2 3 4 5 6
Catagory Manager Engineers Supervisers Operators Survey staff Helpers Total
units 1 1 2 8 2 3 17
Cost/Hr 55 30 25 20 20 10 160
total hours total cost 10 10 10 10 10 10 550 300 500 1,600 400 300 3,650
cos t/m = 3
S 1 2 R .2
7. Crushing a) Primary crushing Crushing shall be done with jaw crusher primarily and then followed by the con crusher for secondary crushing.
Primary jaw crusher
The factors considered in the selection of a primary jaw crusher are: TYPE PE1200×1500 type Material inlet size (mm） Max material size(mm) Material outlet size (mm) capacity (t/h) Eccentric shaft size (r/min) Motor power (kw) weight (t) Overall size（l×w×h）(mm) 1200×1500 1020 150-300 400-800 180 160 100.9 4200×3300×350 0
b) Secondary crushing Cone crusher will be used for secondary crushing
Secondary cone crusher
The factors considered in the selection of a secondary cone crusher are:
PYB 1750 215 25-50 280-480 160 50.3 4870*3800*4192
b) Max. input (mm) c) Adjusting range of output (mm) d) capacity (t/h) e) Electric motor power (kw) f) weight (T)
Overall dimensions (LWH)(mm)
C s er cos ru h t
# Item 1 Expected life 2 Expected utilization 3 Age when sold 4 Purchase price 5 Estim ated residual value 6 Depreciation 7 Rate to cover 9 annual insurrance rate 10 annual insurrance cost 11 rate to cover insurrance 12 annuall cost for zakat 13 Rate to cover other
Units Rate: $/hr Notes 2 yrs 0 30 hrs per yr 00 6 00 hours 00
$ 4,00 00 0,0 $ 0,0 60 00 $ 0,0 per year 17 00 $ 2,38 00 5,0 2 %per year $ ,7 per year 47 00
depreciation 8 Basis for annual insurrance
$ 0,00 per year 10 0
12/2 7+11+13 $33.33 $105.90
14 TOTAL OWNING COST 15 Fuel cost 16 Fuel factor
$ 0.27 per gal 1 .7
17 Fuel consum ption Rate to cover fuel 18 19 Wear parts 20 Factor on cost 21 Expected life 22 Rate to cover wear parts 23 Track chain 25 Expected life 26 Rate to cover tracks 27 Cost of a PM service 28 PM service interval 29 Rate to cover PM 30 Lifetim expected e repair costs 31 Rate to cover repairs 33 TOTAL OWNING AND
8 gal per hour 0 15 6x17 x1 $ 0,00 per set 30 0 1.02 hours 18 00 19 0/2 x2 1 $ 1 set 0 0 23 4/2 x2 5 $ 2,00 0 2 50 2 7/28 $ 1,20 00 0,0 30 /3 1 32 4+
$20.00 $234.18 $340.08 $8.00 $0.00 $170.00 $36.18
This factor covers the cost of fuel and daily oil and lubrication Look to your records
Covers the cost of routine welding etc Look to your records
Look to your records
The average cost of labor and supplies for PM Fixed 20%
32 TOTAL OPERATING COST + + 6+ + 1 18 22 2 29 3
$340.08 1275.285 SR
S m ery of a cos u m ll ts
SR. ITEMS NO 1 Heavy duty Equipm ents 2 drilling blasting 3 Crusher cost 4 Manpower 5 Miscellaneous cost 6 Overheads @10% 7 profit @ 20% Total Am ountunits 4.70 4.20 1.65 1.22 0.32 2.26 4.96 S.R S.R S.R S.R S.R S.R S.R
8. Secondary Breaking Hydraulic breakers will be used for secondary breaking, where breakers will be tasked to reduce a pile of oversized boulders or even tackle primary breaking responsibilities.
9. Plant layout We have planned a proper plant layout keeping in view following concept. a) With a minimum of difficult turning angles, which are always subject to plugging and blockages. b) All crushers and screens will be visible from operator-control area. 10.Screen plants: The screen will be hydraulically raised inclined screens as it is more benicial than horizantel screen. Also Twin screen plants will be used due to their ability to pre-screen material before the secondary crushing stage and allow more complete screening at the finished stage. Many of the new material specifications can be met only with the use of two screens. conveyors: Radial-stacking conveyors, in lengths of 125 ft. and longer will be used instead of free standing conveyors which will allow the operator to put up large quantities of material at relatively little cost. Because of their length, most stacking conveyors will have to be folded for travel. Hydraulic folding and lifting will allow the operator to self-erect with no chance of damage. Conclusions This study provided an overview of the potential export market for Samirock aggregates and as a result offers several conclusions for consideration. Many areas near Makkah Jeddah have abundant aggregate resources, however the constraining factors influencing development is location, quality, quantity and regulatory processes. Although the presence of a high-quality quarry aggregate deposit in Shumaisi is a necessary condition for development, it is by no means a sufficient condition. There are many obstacles to overcome relating to marketing, distribution and access into the highly competitive Saudi market. The long-term trend is that aggregate prices are steadily increasing, reflecting land ownership restrictions, high costs and difficulties in obtaining regulatory approvals. These are factors that increase transportation distances, which in turn drives up the costs of delivered aggregate.
20 11. Product