Mine Machinery Selection

ENGR 5276 - Winter 2024

Lec07 – Dragline Selection and Tires - KPIs

Dr. Ahlam Maremi

Bharti School of Engineering
Laurentian University

F215B
Email: amaremi@laurentian.ca

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Dragline
• Self contained system that loads and dumps material at a
particular location.
• High-capital-cost and low operating costs and labour
requirements.
• Fairly high productivity.
• Long lives 30 to 40 years.
• They can excavate below the level of
machine and outside of pit.
• Safe from unstable slopes, pit
flooding etc.
• Reduces the need for hauling units,
therefore, reducing the cost of
material handling significantly.

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Dragline Facts
• Typically used on flat (tabular) ore bodies.
• In many cases for stripping:
– Coal (US and Australia)
– Phosphate (Morocco)
– Oil sands (historically, 20 years ago!)
• Largest 170 m3 bucket
– Typical now is 125 m3
• Can move 30 to 35 Bm3 Dragline in a coal mine

• Requires a fairly level base for operating on.

• https://www.youtube.com/watch?v=-B_bRWVuITA

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Dragline
• Dragline cycle time:
– It is one of the important parameters in selecting the optimum
dragline.
• Work cycle includes five main components:
– Drag to fill;
– Hoist and swing;
– Dump;
– Return swing and lower; and
– Bucket-spot
• Buckets typically achieve (60 - 80)% of rated volume.
• Disadvantages:
– Less bucket control
– Digging action (75 – 80)% as efficient as shovels.

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Dragline in Open Cast Mining
• The features of an open cast mine are:
– Topsoil removal
– Pre-stripping overburden to provide level grade and meet
digging/dumping dimensional requirements for the dragline
– Overburden removal using a dragline
– Coal removal using a cable shovel and trucks,
– Leveling overburden with a dozer and
– Topsoil replacement, and revegetation of the mined area.

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Dragline in Open Cast Mining
– Pit design has to allow for placement of the
material in a series of parallel adjacent pits
as the mine progresses.
– Overburden material from the current pit is
placed in the previous adjacent pit, from
which product has been removed by
auxiliary equipment.
– Pits are narrow and relatively long.
– The equipment size and the number of
machines employed depend on the
production requirements.
– The dragline is the most common machine
employed for overburden removal.
– Coal is removed by an excavator or shovel
and loaded into trucks for removal from the
mine.

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Dragline Main Components
• Draglines move by walking backwards.
• Each step is about 2 – 3 m.

• Video: Walking Dragline #26 - YouTube

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Dragline Operating Dimensions
• Clearance radius (CR): the minimum free space distance from
dragline positioning centre. This free space is needed for safe
dragline rotation.
• Digging Depth (DD): the maximum digging
depth below its working level.

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Dragline Operating Dimensions
• Clearance height (CH): the height required for dragline swing or
rotation.
• Boom Angle (BA): maximum angle of boom from horizontal.
• Boom foot height (BH): height of boom foot
from dragline operating surface.

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Dragline Operating Dimensions
• Dumping height (DH): the dumping height from highest position
of dragline bucket and dragline operating surface level.
• Boom point height (BP): the height from boom point end to
dragline operating surface level.
• Dumping clearance (DC): the
distance between boom point
end and the highest position
of dragline bucket.
• Point sheave pitch
diameter (PS): diameter
of a pulley block
carrying the main rope
of dragline bucket.

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Dragline Working Dimensions
• Dragline positioning (DP) or Stand-off distance:
– It is the distance from centre of rotation of the dragline to the crest of
the operating bench.
– This distance varies depending on machine size, operational history,
and overburden conditions.

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Dragline Working Dimensions
• Operating radius (OR):
– It is the horizontal distance from the centre of the tub (center of rotation) to
the boom point when the bucket is vertically suspended.
• The maximum distance the dragline can reach in both dragging and spoiling
operations.
– Part of this radius is consumed by the stand-off distance PD.
• Reach factor (RF):
– It is the maximum distance that dragline has to reach during both
dragging and dumping operations. It is an important parameters in
selecting the dragline equipment.

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Range Diagram
– Overburden depth (D)
– Coal (ore) thickness (T)
– Pit width (W)
– Spoil pile angle (𝜃)
– Pit angle or Highwall slope angle (𝛽)
– Reach factor (RF)
– Operating radius (OR)
– Dragline positioning or Stand-off (PD)
– Height of spoil pile (H)
– Stacking height (SH)

Simple Side (cast) Stripping Method Range diagram

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Dragline Selection Procedure
• Mine design:
– Collect mine design criteria.
– Initial estimation of dragline utilization, availability and operation hours, ore
production etc.
– Initial mine design geometry and drawing the range diagram.
• Evaluation:
– Analysis of mine conditions and design dimension.
– Estimate the maximum suspended load (rated suspended load).
– Estimate the reach factor, operation radius, heights.
• Initial selection:
– Initial selection of dragline based on physical dimensions of mine.
– Calculate cycle time and production.
• If production does not align with mine planning expectations, return to evaluation.
• Final selection:
– Select the proper dragline align with the mine planning expectations.
– If you need to optimize your dragline selection return to evaluation step.

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Maximum Suspended Load and Bucket Fill Factor

• Maximum suspended load:

– Maximum suspended load (MSL) can be compared with the rated
suspended load (RSL) parameters in most manufacturer’s chart.
• Bucket fill factor (BF):
– It is a factor which measures difficulty of filling the bucket with broken
materials.
– This factor is also related to the blasting conditions of the overburden.
– Ideally this factor is better to be determined by field investigations,
however, in absence of such data, typical bucket fill factors can be
found in specification sheets.

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Dragline Specifications Example
• CAT 8750 (Manufacturer Chart)

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Dragline Specifications Example
• CAT 8750 (Manufacturer Chart)

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Tires - KPIs

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Off-the-Road Tires
• Off-the-road tires (OTR):
– Proper tire selection, application and
maintenance is the most important factors in
mining economics.
– They operate under a wide variety of
conditions ranging from extremely dry through
wet severe shot rock.
– Operation under variety of speed conditions.
– Climatic conditions, operator skills, and
maintenance practices are important factors
affecting life and unit costs of a tire.
– No one tire can meet all requirements on any
one machine and perhaps not even one job.

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Off-the-Road Tires
• The optimum tire selection for a specific machine on a given
job should be a joint decision between the mining engineer
and tire supplier.
• When job conditions change, it may be desirable to select a
different tire configuration to meet the new requirements.

• Basic functions of a haul truck tire:

– Absorb shocks,
– Transfer traction and braking forces to the surface,
– Change and maintain direction of travel,
– Support the load.

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Off-the-Road Tires
• Based on application of the tire, we can classify the off-the-
road tires into the following three categories:
– Transport tire:
• For mining equipment that transport material such as rigid-body haul
trucks.
– Work tire:
• Normally applied to slow moving equipment such as graders and
loaders.
– Load and carry:
• Wheel loaders engaged in transporting as well as digging.

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Off-the-Road Tires
• Two distinct tire constructions are:
– Bias Ply: designated by “-”
– A bias ply tire has its plies in a crisscross pattern as they overlap each
other.
• For example, a 45/65-45 tire would be a Bias tire

– Radial Ply: designated by an “R”

– The cord plies are arranged at 90 degrees to the direction of travel, or
radially
• For example, a 45/65R45 is a Radial one.

• Radial tires are more predominant in North American surface

mines and heavy earthmoving operations.

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Types of Tires
• Tire construction:
– Beads
– Body plies
– Breakers or tread piles
– Sidewalls
– Belts

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OTR Tires
• Radial tires cost 10% to 20% higher, however, they are
proven to be a more durable product, achieving a 30% to
40% longer tire life.

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Spillage During Loading
• The tire shown in the picture has the following designation:
– 59/80R63
– 59 width (W)
– 80 aspect ratio H/W %
– 63 Drim
– R: radial ply

• What is the tire diameter (ø)?

tire  Drim + 2 H
H D𝒓𝒊𝒎
= 0.8, W = 59in → H = 0.8  59 = 47.2in
W
Drim = 63in
tire  63 + 2  47.2 = 157.4in 4m

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Some Tires Dimensions, Weight & Load Ratings

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Size Comparison

Aspect ratio (H/W) 0.80 Aspect ratio (H/W) 100%

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Calculation of the Tire Inflation Pressure
• The 7% rule:
– The maximum allowed deformation (vertically) of a tire when loaded
is 7%.
– This means tire deformation 𝛿=0.07(𝜙) where 𝜙 is the tire diameter.

• Inflation pressure under tare loading (no payload) should

generate less than 7% deformation.

• Footprint area (A): will increase as deformation increases.

𝐴 = 1.35 𝛿𝜙

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Tire Geometry Scale Formula

𝐴 = 1.35 𝛿𝜙

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Tire Inflation Pressure
• Tire inflation pressure:
– It is the amount of air inside a tire recommended by a truck
manufacturer.
– This inflation pressure or air pressure is measured by PSI or pounds
per square inch, using a tire pressure gauge.
• Tires that contain the specified amount of air pressure last
longer and contribute to truck safety.
• Low tire pressures affect braking distances and provide less
responsive steering and handling.
– This can be especially dangerous when an emergency stop, or
sudden evasive maneuver is needed to avoid a collision.

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Calculation of the Tire Inflation Pressure
• Example:
– What is required inflation pressure for 59/80R63 on 797 hauler at
GVW 623 tons

GVW = Tare + Payload

tire = 4m (from previeous example)
Tire deformation  = 0.07tire = 0.07  4 = 0.28m
Footprint Area A = 1.35    tire = 0.35  0.28  4 = 1.512m 2
F 623  9.81/ 6
Tire inflation pressure P = = = 674kpa  98 psi
A 1.512
1 kpa  0.1450 psi

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Load Transfers
• Remember that air does not carry the load!
• Load is transmitted directly from the rim to the ground
through the tire carcass.
• Balanced by the ground contact pressure through the tire
footprint area

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Inflation Pressure vs Tire Life
• Between low and high tire pressure, having less air in your tires is
worse for them.
• They can wear out quicker, handling will be decreased and there
is a greater chance of them blowing.
• Although low tire pressure is worse for your vehicle, high PSI is
not risk free either.

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Influence of High g Events on Tire Life
• g-level (g-force): is a measurement of the type of force per unit
mass, usually acceleration, that causes a perception of weight.
• A g-force of 1g is equal to the conventional value of gravitational
acceleration on Earth which amounts to 9.8 m/s2.

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Tire Life & Ground Condition Estimator

 NM 
L = E 1 −
 G 

– L: expected (experienced) tire

life (hrs)
– E: tire life suggested by OEM
– N: number of events greater
than adverse g level per hr
– M: magnitude of adverse g
level (1.3 g - 1.5 g)
– G: operating and ground
conditions factor / hr

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Tire Life Estimation – Example
• What is the expected tire life in hours (L) knowing that the tire life
suggested by OEM (E) is 8,000 hours. The operating and ground
conditions factor (G) is 45 per hour and magnitude of adverse g
level (M) is 1.5 g and the number of events greater than adverse
g level per hour is 4 (4 events per hr > 1.5 g).

 NM 
L = E 1 −
 G 
E = 8, 000hr N=4 events  M = 1.5 g / hr G = 45 / hr
 4 / hr 1.5 
L = 8, 000 1 − = 6,933hrs
 45 / hr 

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Ground Condition Estimating - Example
• The expected tire life in hours (L) is 4,000 and the tire life
suggested by OEM (E) is 8,000 hours. What is the operating and
ground conditions factor (G) knowing that the magnitude of
adverse g level (M) is 1.5 g and the number of events greater than
adverse g level per hour is 26 (26 events per hr > 1.5 g).

 NM 
L = E 1 −
 G 
26 events  1.5 g / hr E = 8, 000hrs L = 4, 000hrs
L NM NM L L 4, 000
= 1− →→ = 1 − →→ = = 0.5
E G G E E 8, 000
1 − 0.5 = 0.5
NM 26 1.5
= 0.5 → G = = 78 per hour
G 0.5
The operating and ground conditions factor G = 78 per hour

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Oil Sand Issues With Tires

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Source of Heat in Tires
• Higher torque generates more heat.
• Higher speed generates more heat.
• Tire wear is exponentially proportional to torque (load) and
speed.
• Ground conditions exponentially affect all of the above.

Maximum Temperature Area

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Factors Affecting Tires Life

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Spillage During Loading

Spillage

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Sidewall Cuts

Sidewall Cuts

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Spilled Materials on the Haul Road

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Mechanical Separation Failures

• The tread rubber separates

from the tire casing.
• Usually initiating in the
shoulder area.
• Failures mainly the result
of high tire load and speed.
• Particularly during
cornering or turning of the
truck.

Mechanical separation of the tire

shoulder (55/80R63)

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Sidewall Issues
• Frequently happens when attempting to maneuver around
spillage.
• Truck drivers often clip the spillage with a tire shoulder or
sidewall resulting in a sidewall cut failure.

Sidewall damage (55/80R63)

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Tonne Kilometer Per Hour
• Tonne kilometer per hour (TKPH) is one of important KPI used to
select the appropriate tire type for a mine site, also it is used to
monitor the operational environment the tires are subjected to.
• The tire manufacturers classify their products according to TKPH.
• TKPH rating system is used by the manufacturers and reflects a
maximum workload capacity of a tire.

TKPH = Average load per one tire × Average cycle speed

 empty load one tire +loaded load one tire 
Average load per one tire =  
 2
 Round trip distance×Number of trips per shift 
Average cycle speed =  
 Total shift hrs

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Case Study Example – OEM TKPH
• Truck weight is 140 ton, and the load is 360 ton. Maximum
speed is 30 km/hr.
• Loaded, ideal situation.

Max speed, Vmax = 30km / hr → should not exceed 30km / hr

(loaded & unloaded)
Loaded truck:
55 / 80 R63
GVW = 360 ton + 140 ton = 500 ton
Each tire 500/6= ton/tire

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Case Study Example – OEM TKPH
Unloaded truck: 50% front to rear
Load for the front =140/2=70ton
Load per tire for the front=70/2=35ton
Load for the back =140/2=70ton
Load per tire for the back=70/4=17.5ton
Average load per tire front (loaded & unloaded) = (500/6+35)/2=59.2ton
Average load per tire back (loaded & unloaded) = (500/6+17.5)/2=50.42ton
Total avaerage = (59.2 + 50.42) / 2 = 54.81ton
TKPH = 54.81 30 = 1,644.3tkph

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Real Time TKPH Analysis
• Mine dispatch records a 220-ton payload truck with 165-ton tare
delivers 6,120 ton to the crusher in a 12-hour shift.
• 1 hour of total coffee and launch break were taken in the shift.
• The truck travels 4km each way between the shovel and crusher.
• What is mine average TKPH for the truck over the shift?
GVW = 165ton + 220ton = 385ton
6120ton in 12 − hour shift (1 hour for lunch break)
Round trip distance = 4km  2 = 8km
6,120
Number of trips = = 27.8
220
11hr
Time per round trip = = 0.4hr
27.8
Distance 8km
Average speed = = = 20kph
Time per round trip 0.4hr

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Real Time TKPH Analysis

Loaded:
Load per tire = 385ton / 6
Unloaded: 50% front to rear = 165 / 2ton
Total load front = 82.5ton
Load per tire front = 82.5 / 2 = 41.25ton
Total load rear = 82.5ton
Load per tire rear = 82.5 / 4 = 20.625ton
(385ton / 6) + (41.25ton)
Total average load front (loaded & unloaded) = = 52.7ton
2
(385ton / 6) + (20.625ton)
Total average load rear (loaded & unloaded) = = 42.4ton
2
52.7 + 42.4
Average load (front and back) = = 47.55 ton
2
Mine average TKPH = 47.55ton  20km / hr = 951 tkph

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Real Time TKPH Analysis
• Why?
– To build a complete TKPH picture and compare to OEM and
conventional mine averaged value.
– Identify the reason for having lower than expected tire life exists.
– Evaluate operational and environmental control measurement in the
mine.
– Increase the tire life
– Identify issues contributed to having high TKPH (payload in balanced
and ground condition)
– Reduce the maintenance costs of both the hauler and tires

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Excessive Speed

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Don’t Forget!

• Check your LU email and D2L regularly.

• Review additional resources available on D2L
• Midterm March 7th – Class time – Lec01 to 05 – Location TBD

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