Table Of Content

1.0 Statement Of Problem…………………..………………..……………………………….3

2.0 Selection of suitable truck and shovel: ……………..……………..………………………4
2.1 Truck: ……………..……………..……………..……………..………………………4
2.2 Shovel:… ……………..……………..……………..……………..……….………….5
2.3 Shovel Productivity:… ………………..……………..……………………….......6

2.4 Production in waste: ……………..……………..…….………………………….6

2.5 Truck Productivity :…… ………………..……………..……………………......7

2.6 Number of trucks Calculations:……. …………………………………………..7
2.7 Result. ……………..……………..………………..……………..………………….....11

3.0Discussion ……………..……………..………………..……………..…………..…………..……….12

4.0 Conclusion……………..……………..………………..……………..…………..…………..………12

5.0 References……………..……………..………………..……………..…………..…………..……...12

Tables:

Table 1………………..……………..……………..……………..………………………………...10

Figures:

Figure 1……………..……………..……………..……………..………………..…..……………..4

Figure 2……………..……………..……………..……………..……………..………..…………..5

Graph:

Graph 1……………..……………..……………..…………………....……………..……………..8

Graph 2……………..……………..……………..……………..…………..………..……………..8

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 1.0 Statement Of Problem:

Achiever Group of Industries are going to establish a refinery in Chakwal. To provide the raw material, An
Engineer is hired to provide 300,000 tons of ore with stripping ratio of 3:1. Density of Ore and waste is 2.65 t/BCM
& 2.7 t/BCM respectively. Cycle time is 60 seconds with variance of 15 seconds, dipper capacity is 42 m 3, fill factor
is 75 %. Availability and Utility of equipment is 80 % and 90% with variance of 5 and 1 percent respectively. Swell
factor of rock and waste is same that is 1.5. Swing factor is 1 but propel factor is 85 percent. You are required to
calculate the number of shovels and trucks for working in waste and ore with only shift of 12 hours. Additionally,
find out the minimum and maximum production with probability of the production ranging between the maximum
and minimum production levels. Keeping the whole procedure in mind, what are the factors that can disturb the
production capacity above or below the calculated range. Provide costs of the trucks and shovels with the capacity
from different manufactures as well.

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2.0 Selection of suitable truck and shovel:

Selection of mining equipment plays a very important role in overall production and cost. As we move toward
advance and bigger equipment our capital cost increase as well as productivity also increases. Selection
parameters lie under different factor that are discussed in report. The Selected model for truck and shovel are as
follows:

2.1 Truck:

Selected Truck from cat handbook is = 797F Gross weight = 623690kg, 1375000lb.

Empty operating weight = 273570kg, 603118lb.

Target payload = 370 – 400 tons

Capacity = 240m3

Figure 1:Catapillar 797F

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2.2 Shovel:

Selected shovel for project = 7495HD (FROM CAT HANDBOOK)

Payload = 90tons

Dipper Range = 19-61m3, 25-80yd3 dipper range given = 42

Figure 2: Power Shovel Catapillar 7495 HD

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2.3 Shovel Productivity:

Daily ore tonnage = 300000 tpd

Waste produce = 300000 ×3= 900000 tpd

=900,000/2.65

= 339622.64 BCM/day Shovel production equation

Pore= k/𝐶𝑡 × 𝐷𝐶 × 𝐹𝐹𝑆 × 𝐴 × 𝑈 × 𝑆. 𝐹 × 𝑃𝐹

Pore=(3600/60) × 42 × 0.75 × 0.80 × 0.90 × 1 × 0.85 = 1156.68 ton/hr

𝛾𝐿(𝑜𝑟𝑒) = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦/ 𝑠𝑤𝑒𝑙𝑙 𝑓𝑎𝑐𝑡𝑜𝑟

(𝑜𝑟𝑒) = 1.76 𝑡⁄𝐿𝐶𝑀

Pore = 1156.68 LCM/hr × 1.76 = 2035.46 𝑡⁄ℎ one shovel is scheduled on operating 12 hrs.

Pore = 2035.46 𝑡⁄ℎ𝑟 ×12 hrs = 24429.08 tpd

No. of shovels in ore = 12.28 shovels =13

2.4 Production in waste:

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑖𝑛 𝑤𝑎𝑠𝑡𝑒 = 𝑘/𝐶𝑡 𝑥 𝐴 𝑥 𝑈 𝑥 𝐹. 𝐹 𝑥 𝑆. 𝐹 𝑥 𝑃𝑓 𝑥 𝐷𝑡

= 3600/60 𝑥 42 𝑥 0.75 𝑥 0.80 𝑥 0.90 𝑥1 𝑥0.85

= 1156.68𝐿𝐶𝑀/ℎ𝑟

𝐿𝑜𝑜𝑠𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 2.7/1.5 = 1.8 𝑡 /𝐿𝐶𝑀

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 1156.68 𝑥 1.8 = 2082.024𝑡/ℎ𝑟.

Productivity for 12 hours = 2082.02 𝑥 12 = 24984.24 𝑡/6ℎ𝑟.

Number of Shovels = 900000/24984.24 = 36.02 Shovels = 36 Shovels.

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2.5 Truck Productivity :

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 𝑘/𝐶𝑡 𝑥 𝐷𝑡 𝑥 𝐴 𝑥 𝑈 𝑥 𝐹𝐹𝑏

Cycle time is given by

𝐶𝑡 = 𝑆𝐿𝑡 + 𝐿𝑡 + 𝑇𝐿𝑡 + 𝑆𝐷𝑡 + 𝐷𝑡 + 𝑇𝑒𝑡 + 𝑊𝑡

For travelling time empty and travelling time Loaded graphs of cycle time can be used for that we need to have
effective grade…

𝐺𝑟𝑎𝑑𝑒 𝑎𝑠𝑠𝑢𝑚𝑒𝑑 = 4% 𝑖𝑛 𝑙𝑜𝑎𝑑𝑒𝑑 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛

𝐺𝑟𝑎𝑑𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝐺𝑅𝐹 𝑥 𝑉𝑊

𝐺𝑅𝐹 = 𝐾 𝑥 % 𝑔𝑟𝑎𝑑𝑒

𝐺𝑅 = 10𝑘𝑔/𝑡 𝑥 687.50𝑡 𝑥 4% = 27500𝑘𝑔𝑓

R𝑜𝑙𝑙𝑖𝑛𝑔 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝑅𝑅𝐹 x 𝑉𝑊

𝑅𝑅𝐹 = [𝑅𝑓 + 𝑅𝑠 𝑥 𝑃] 𝑥 1.075 + 0.115𝑉 – 9.0

𝑅𝑓 = 20𝑘𝑔/𝑡 (𝑝𝑙𝑦 𝑡𝑖𝑟𝑒𝑠)

𝑅𝑠 = 6𝑘𝑔/𝑡. 𝑐𝑚

𝑃 = 𝑝𝑒𝑛𝑒𝑡𝑟𝑎𝑡𝑖𝑜𝑛 = 6𝑐𝑚 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

𝑉 = 𝑉𝑒ℎ𝑖𝑐𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 (𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑖𝑛 𝑚𝑖𝑛𝑒)

𝑊 = 𝑡𝑟𝑢𝑐𝑘 𝑤𝑒𝑖𝑔ℎ𝑡 = 687.50𝑡

𝑅𝑅𝐹 = [20 + 6 𝑥 6] * 1.075 + 0.115 * 25 − 9.0 = 54.075 𝑘𝑔/𝑡 𝑅𝑅 = 54.075 * 687.50 = 37176.56 𝑘𝑔𝑓.

𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 37176.56 + 27500 = 64676.56 𝑘𝑔𝑓

𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑔𝑟𝑎𝑑𝑒 = %𝐺𝑅 + % 𝑅𝑅

𝑅𝑅% = 𝑅𝑅𝐹 / (10𝑘𝑔/𝑡) 𝑖𝑛 %

= 54.075/10 = 5.4075 %

𝐺𝑅 % = 𝐺𝑅𝐹 / (10𝑘𝑔/𝑡) 𝑖𝑛 %

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 = 40/10 = 4%

𝐸𝐺 = 5.4 + 4 = 9.4 %

Now cycle time graphs can be used to calculate Travel loading time and Travel empty time for 500m distance
(assumed)

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So, total travel time = 2.833 minutes

Now assuming

SLt = 15s

SDt = 10s

Shovel loading cucle time = 45sec

Wt = 1.5mins

Dt = 1.0 min

Ct = 15s + 10s + 45s +90sec +60 sec + 170sec = 390 sec = 6.5 minutes.

For productivity considering Availability = Utilization = 90% FFb= 0.97

Productivity = 60/6.5 x 370t x 0.90

= 2683.46 t/hr

Now for 12 hours in ore productivity = 2683.46 x 12 = 32201.52 tons/day

Waste productivity for 12 hours = 2683.46 x 12 = 33201.52 tons/ day.

2.6 Number of trucks Calculations:

For ore number of trucks require = 300000/32201.52 = 9.31 Trucks

For waste production = 900,000/33201.52 = 27.10 trucks

Total = approximately 8 number of trucks are required

Hence total number of trucks = 36 trucks

Shovel variability in production by changing A (availability), U (utilization), Ct (cycle

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time).

The following data can be used to find shovel variability in production.

Table 1: table

Variable Expected Value Variance

(sec)2
Cycle Time 60s 15

0.80 5
Availability
0.90 1
Utilization
0.75 NIL
Fill Factor of Shovel

Taking Derivation of productivity equation with respect to Ct we have,

𝜕𝑃𝑠 3600
____ = ________ × 42 × 0.75 × 0.80 × 0.90 × 0.85 = −19.278
𝜕𝑐 (60)

Now taking second derivative with respect to Ct we have

𝜕𝑃𝑠 2 × 3600
_____ =____________ × 42 × 0.75 × 0.80 × 0.90 × 0.85 = 0.64
𝜕𝑐 (60)

Taking Derivation of productivity equation with respect to A (availability) we have,

𝜕𝑃𝑠
_____
𝜕𝐴 = k/𝐶𝑡 × 𝐷𝐶 × 𝐹𝐹𝑆 × 1 × 𝑈 × 𝑆. 𝐹 × 𝑃𝐹

𝜕𝑃𝑠
____ = (3600/60 )× 42 × 0.75 × 0.90 × 0.85 = 1445.85 =14.45 (t/hr % A)

𝜕𝐴

Now taking second derivative with respect to A we have,

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𝜕2𝑃𝑠
________ =0
𝜕𝐴

Now taking derivative with respect to random variable U (utilization),

𝜕𝑃𝑠
_____
𝜕𝑈 = k/ 𝐶𝑡 × 𝐷𝐶 × 𝐹𝐹𝑆 × 𝐴 × 1 × 𝑆. 𝐹 × 𝑃𝐹

𝜕𝑃𝑠 3600
_____= ________ × 42 × 0.75 × 0.8 × 0.85 = 1285
𝜕𝑈 60

=12.85 (t/hr %U)

E[P] ={ 3600/60 x 42x0.75 x 0.80 x 0.90 x 0.85}+1/2{0.64x15+0x5+0x1}

= 1161.48 LCM/hr

[𝑃𝑠] = (−19.278)2 × 15 + (14.45)2 × 5 + (12.85)2 × 1 = 6783.75 (𝐿𝐶𝑀⁄ℎ𝑟)2

Standard deviation = √6783.75 = 82.4 𝐿𝐶𝑀⁄ℎ𝑟

2.7 Results:

Minimum value = 1156.68 – 82.36 = 1074.32 𝐿𝐶𝑀⁄ℎ𝑟

Maximum Value = 1156.68 + 82.36 = 1239.04 𝐿𝐶𝑀⁄ℎ𝑟

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3.0 Conclusion: Required parameter were calculated and mentioned in this report. Regarding of the
procedure and data available, there were some doubts but later on these were vanished due to group
discussion and engineering problem was solved easily.

4.0 Discussion: Total no. of trucks, shovel, their individual and combined production, their cycle time,
selection and all other parameter were solved in detail.

5.0 References:
https://www.google.com.pk/search?q=caterpillar+797F+dimension&source=lnms&tbm=isch&sa=X&ved=0ah
UKEwi05eHGgq3bAhVC1RQKHWYPAaYQ_AUICigB#imgrc=9vz2LraYy_58tM:

https://www.google.com.pk/search?q=7495HD&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiit72vg63bAh
XFwBQKHa7NA6AQ_AUICygC

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