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OPEN PIT DESIGN AND SCHEDULING -

I.T SOLUTION FOR LONGTERM MINE PLANNING
D.L.R. Prasad
1
, P. Srinivas
2
, B. Sambasivarao
3
, *D. Gopinath
4


INTRODUCTION

Information Technology has changed the way we live. Mining is no exception. Mining
information systems have emerged encompassing all aspects of mine planning. Real time
analysis of data is now possible that helps the mine administration to function effectively.
Software is now available that covers the entire gamut of mine functions.
The Singareni Collieries is now ahead in utilizing the computerized mine planning and
completed design & scheduling of an opencast project on long term planning module Apollo
of Minex software.

FEATURES:
Minex is an integrated modular software including Survey, deposit evaluation, mine
planning and design, production scheduling and equipment simulation. The user has the
flexibility to select modules as per requirement.
Generation of Borehole database
Generation of reliable Geomodel
3D visualization of seam horizons/faults
Generation of Reserves Database
Pit Optimisation
Open Pit Design and Scheduling
Design of Haul roads, Earth works and Spoil dumps
Underground mine planning and scheduling
Generation of Mine Reserves Database
Production Scheduling by target or equipment
Generation of Plans, Sections and reports

1. Chief General Manager, 2. Dy. Supdtg. Er, 3. Sr. Survey Officer,
The Singareni Collieries Company Limited (A government Company), Kothagudem, Andhra Pradesh., INDIA
* 4. Under Manager Now working at Surpac Minex, Hyderabad, INDIA




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A project is taken up at Singareni Collieries to design a pit, spoil dump and production
scheduling using Apollo & Orion modules of MINEX software, to get the desired pit design
and stage wise plans for preparation of feasibility report.


PROJECT DETAILS

The Pit - A is designed upto 150 m depth of Bottom Seam. There are two down
throw and one up throw faults in the property.

SUMMARISED DATA
Sl.
No
Description
1.0 INSITU RESERVES M.T 3.497
1.1 MINEABLE RESERVES M.T -----
1.2 TOTAL OVERBURDEN M.Cu.m 28.872
1.3 AVG.STIPPING RATIO Cu.m/T 8.3
2.0 BOREHOLE DENSITY No./Sq.Km 35.58
3.1 MAXIMUM STRIKE LENGTH ALONG
SURFACE
Meters 933
3.2 MAXIMUM STRIKE LENGTH ALONG FLOOR Meters 718
4.1 MAXIMUM WIDTH OF THE QUARRY ALONG
SURFACE
Meters 621
4.2 MAXIMUM WIDTH OF THE QUARRY ALONG
FLOOR
Meters 420
5.1 MINIMUM DEPTH OF THE QUARRY Meters 28.00
5.2 MAXIMUM DEPTH OF THE QUARRY Meters 150.0
6.1 FLOOR AREA OF QUARRY Ha. 21.45
6.2 AREA OF EXCAVATION ON SURFACE Ha. 45.15
7.0 AVERAGE GRADIENT OF THE SEAM 1 in 3.5






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8.0 DETAILS OF WORKABLE SECTIONS
PIT-A SECTION
MINIMUM MAXIMUM
- MIDDLE SEAM 4.65 8.53
PARTING 14.63 17.65
- BOTTOM SEAM 3.18 4.41

9.0 QUALITY
UHV(Kcal/kg) Grade
PIT A 4758 D

10.0 TECHNOLOGY SELECTED : SHOVEL-DUMPER COMBINATION
11.0 INSTALLED CAPACITY : 0.60 M.T per annum
12.0 LIFE OF THE PROJECT : 6 YEARS

OPENPIT DESIGN

PIT BOUNDARY
Quarry surface limit is defined on the basis of quarry floor limits by considering the final
slope of 45 degrees from incrop and 150m depth of Bottom seam at highwall side.
By considering the geological model of Pit-A, the bottom seam and middle seam model
grids are merged with BOW (Base Of Weathering) surface at incrop side to generate benches
upto the pit boundary/surface quarry limit.

BENCH DESIGN
The bench design is followed as per bench elevation at 10m interval with 70 slope and
6.4m berm. To generate the bench crest and toe at every 10m elevation, SQL (Structured
Query Language) programme is used. The bench grids formed in the pit are restricted upto
topography / floor of the bottom seam as per the requirement.







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FIG.1





FIG.2






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Final pit benches are restricted to the Bottom Seam floor and topography as shown
below:

FIG.3
STRIP DESIGN
13 no. of strips with crest and toe in strike direction at 40m interval with 70 degrees of
slope and strip berm of 6.4 mtrs are projected on each bench grid.


FIG.4



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BLOCKS FORMATION
The pit is divided into number of blocks using layout lines across the strips at 40m
interval. Each block is assigned a number to report the reserves.

FIG.5 BLOCK DESIGN



FIG.6


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FIG.7 SECTION SHOWING THE BENCHES, STRIPS AND BLOCKS

MINE RESERVES
Mine Reserves database is created with Codes and Layers validated and loaded.
Merge model is created for the Pit - A for the selected layers. Layer wise mine reserves of the
pit can be obtained as desired.


FIG.8

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FIG.9 TYPICAL MERGED MODEL


FIG.10
Detailed Pit Reserves generated for Pit/Bench/Strip/Block is given at Annexure-1. Also
generated the status report along with stripping ratios is shown at Annexure-2. By studying
the detailed report of Pit reserves block wise, it is easy to identify the blocks in the designed pit
for scheduling.



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PRODUCTION SCHEDULING
Scheduling is primarily aimed at sequencing mining operations in a pit/ multi strip/multi
bench for coal or other layers. Target scheduling option is selected for the purpose.

TARGET SCHEDULING: This is the suitable method of scheduling to obtain a particular coal
target over a time period and to generate stage plans. This macro scheduler finds applications
in feasibility studies and production of long-range mine plans.
Details of Target Scheduling:
The project is proposed to extract coal with 0.60M.T per annum as installed capacity.
Accordingly a suitable calendar is prepared for the project. For each scheduled block, reserves
are reported and extraction of the quarry is planned for each coal seam/waste at every stage.
Exposed blocks at the end of 1
st
year, 3
rd
year, 5
th
and final years of Pit-A are converted
as exposed grids. In a grid format the pit status can be used for dump design and/or back fill
planning.

FIG.11 STAGE - AT THE END OF 1 YEAR

Reports are generated for the quantity of coal extracted and waste removed at each
stage {at the end of 1
st
year, 3
rd
year, 5
th
year and 6
th
(final) year}.
Eg: Annexures-3.



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DETAILS OF COAL PRODUCTION & OVERBURDEN REMOVAL IN PIT- A

Cumulating
End of
the Year
Coal (MT) OB (M.cu.m) Str. Ratio
1 0.30 6.233 20.77
3 1.50 18.621 12.41
5 2.70 26.995 10.00
6(Final) 3.497 28.872 8.30


HAUL ROAD DESIGN

Haul roads are designed at 6.25% gradient with a width of 20m on exposed
grids/triangles keeping batter slopes at 57 degrees cut and 36 degrees fill.


FIG.12 HAUL ROAD DESIGN




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SPOIL DUMP DESIGN
Proposed area of overburden dumping is digitized. Dump design is made for every
stage of the project keeping the dump deck height as 30m, dump slopes at 28 degrees and
berm width as 30 mtrs for allowing safe transport.

FIG.13 FINAL EXTERNAL DUMP OF PIT-A
TRUCK SIMULATION
Truck and Shovel simulation system simulates the movements of a vehicle through a
network of roads and ramps and estimates traveling time and truck fleet requirement. It can
calculate the truck productivity (bank volume per truck hour).
The input to the program is divided into data sets that define the characteristics of
segments of routes, vehicle acceleration and deceleration potential at various velocities, and
shovel operating parameters (Annexure - 4).
The following parameters are considered for truck simulation at a particular stage of
excavation.
Shovel bucket cubic capacity 2.80
Truck load by weight 25.00
Swell factor 1.20
Insitu density 2.20
Results are: i) Truck cycle time (minutes) 14.98
ii) Est. Min truck fleet required 3.94 (say 4)
iii) Bank volume per truck hour 46

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FIG.14

2D PLANS OUTPUT

The scheduling output of a stage on 2D plan is visible as blocks as shown below.

FIG.15



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It is felt very difficult to get the 2D plans output as desired in the form of crest and toe
lines shown below.

FIG.16 STAGE PLAN END THE END OF 1st YEAR

INCROP
D
I
P
DE-COALED AREA

FIG.17 STAGE PLAN END THE END OF 3rd YEAR

How ever, to overcome the problem, the scheduling output at a particular stage is
digitized using Vista functions.



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CONCLUSION
Mine planning, designing and scheduling of an open pit are now made the mining
system easy.
Saves time in preparing number of alternative pit designs and production schedules with
different design and schedule parameters. A best suitable pit design and production schedule
can be selected.
Quick reporting of reserves of each layer / bench / strip / block is possible.
Year/month/day wise reports can be generated for the extracted volume of OB and Coal at the
end of each schedule.
The authors felt the necessity of 2D plans output to be customized rather than the
tedious process of digitizing the position of quarry at every end of the schedule.

ACKNOWLEDGEMENT
The Authors are thankful to the Singareni Collieries management for providing the
necessary software, hardware and encouragement in achieving the desired outputs through
Minex Software at SCCL.

REFERENCES
Getting Started with Apollo Mine Design & Reserves, ECS International Pty Ltd,
Surpac Minex Group, Australia.
Mark Kelly, Peter Alexander, Surpac Minex Group, Australia, Training programmes on
Apollo and Orion modules of Minex Software at Singareni Collieries.















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DETAILED REPORT OF MINE RESERVES DATABASE
(PIT/BENCH/STRIP/BLOCK/LAYER WISE)

Seam Bench Volume Volume Tonnes
Waste Coal Coal
--------------------------------(Cu.m)----(Cu.m)----------------Pit A
-------
WEATH 2 32343
WEATH 3 339153
WEATH 4 1281332
WEATH 5 2889683
MS 5 38842 4199 6508
BS 5 10154 1479 2293
WEATH 6 3316494
MS 6 464363 21350 33093
BS 6 54944 11827 18331
WEATH 7 1917337
MS 7 1418174 58957 91383
BS 7 168046 32860 50933
WEATH 8 278993
MS 8 2574173 98257 152299
BS 8 281292 54761 84880
MS 9 2480027 110828 171783
BS 9 295613 70419 109149
MS 10 2124540 132633 205581
BS 10 281074 69416 107595
MS 11 1787487 147243 228227
BS 11 277216 63373 98229
MS 12 1464424 160777 249205
BS 12 283244 61701 95637
MS 13 1156298 155777 241454
BS 13 294825 64532 100025
MS 14 877736 141768 219740
BS 14 282969 68224 105747
MS 15 614988 137683 213408
BS 15 261715 63863 98987
MS 16 369829 134534 208527
BS 16 243592 58933 91346
MS 17 160637 110064 170600
BS 17 226981 62352 96645
MS 18 40438 43235 67014
BS 18 190281 57734 89488
MS 19 8387 1972 3056
BS 19 77560 43474 67385
BS 20 6878 11825 18329
--------- --------- ---------
TOTAL 28872068 2256047 3496877
-----------------------------
SUMMARY Volume Volume Tonnes
Waste Coal Coal
Pit A
-------
WEATH 10055337
MS 15580355 1459275 2261877
BS 3236385 796773 1234999
--------- --------- ---------
28872068 2256047 3496877
ANNEXURE - 1

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STATUS REPORT OF MINE RESERVES DATABASE (PIT/BENCH/STRIP/BLOCK/LAYER
WISE)

Pit Ben Str Blk Layer % % % % %UWed%LWed %Reh Volume
No. No. No. No. ID. Expo Surf Prem Mine*%R.D.*%Ash*EffS/R* Tonnage*Thick
--- --- --- --- ----- ---- ---- ---- ---- ----- ---- ------ -----
100 2 1 1 WEATH 100 0 0 0 439 4.4
100 2 1 2 WEATH 100 0 0 0 5765 3.0
100 2 1 3 WEATH 100 0 0 0 3830 1.8
100 2 1 4 WEATH 100 0 0 0 19 0.1
100 2 2 1 WEATH 100 0 0 0 8598 3.4
CONTD
------------------------------------------------------------------------
INTENTIONALLY LEFT THE BLANK SPACE
------------------------------------------------------------------------
100 19 12 10*MSC 0 0 0 0* 1.55* * 8.4* 667* 1.1
100 19 12 10 BSIB 0 0 0 0 2184 3.6
100 19 12 10*BSC 0 0 0 0* 1.55* * 8.4* 2291* 1.6
100 19 13 3*BSC 0 0 0 0* 1.55* * 8.4* 118* 0.4
100 19 13 4 BSIB 0 0 0 0 663 1.7
100 19 13 4*BSC 0 0 0 0* 1.55* * 8.3* 6097* 2.8
100 19 13 5 BSIB 0 0 0 0 988 2.0
100 19 13 5*BSC 0 0 0 0* 1.55* * 8.3* 6311* 3.7
100 19 13 6 BSIB 0 0 0 0 2353 3.3
100 19 13 6*BSC 0 0 0 0* 1.55* * 8.3* 5978* 3.6
100 19 13 7 BSIB 0 0 0 0 6651 6.5
100 19 13 7*BSC 0 0 0 0* 1.55* * 8.3* 4127* 2.3
100 19 13 8 BSIB 0 0 0 0 3559 6.9
100 19 13 8*BSC 0 0 0 0* 1.55* * 8.3* 1904* 2.5
100 19 13 9 MSOB 0 0 0 0 1626 9.4
100 19 13 9*MSC 0 0 0 0* 1.55* * 8.3* 866* 2.1
100 19 13 9 BSIB 0 0 0 0 1498 4.6
100 19 13 9*BSC 0 0 0 0* 1.55* * 8.3* 1582* 3.0
100 20 9 14 BSIB 0 0 0 0 180 1.8
100 20 9 14*BSC 0 0 0 0* 1.55* * 8.3* 1949* 2.1
100 20 9 15 BSIB 0 0 0 0 2175 4.4
100 20 9 15*BSC 0 0 0 0* 1.55* * 8.3* 3455* 1.7
100 20 10 12 BSIB 0 0 0 0 1745 3.0
100 20 10 12*BSC 0 0 0 0* 1.55* * 8.3* 2734* 1.3
100 20 10 13 BSIB 0 0 0 0 408 1.4
100 20 10 13*BSC 0 0 0 0* 1.55* * 8.3* 3693* 2.3
100 20 10 14 BSIB 0 0 0 0 1432 3.6
100 20 10 14*BSC 0 0 0 0* 1.55* * 8.3* 2543* 3.6
100 20 10 15 BSIB 0 0 0 0 359 8.2
100 20 10 15*BSC 0 0 0 0* 1.55* * 8.3* 69* 1.1
100 20 11 11 BSIB 0 0 0 0 223 2.2
100 20 11 11*BSC 0 0 0 0* 1.55* * 8.3* 750* 1.0
100 20 12 9*BSC 0 0 0 0* 1.55* * 8.3* 50* 0.3
100 20 12 10 BSIB 0 0 0 0 343 3.1
100 20 12 10*BSC 0 0 0 0* 1.55* * 8.3* 1510* 1.4
100 20 13 4*BSC 0 0 0 0* 1.55* * 8.3* 8* 0.1
100 20 13 6*BSC 0 0 0 0* 1.55* * 8.3* 31* 0.1
100 20 13 7*BSC 0 0 0 0* 1.55* * 8.3* 252* 0.4
100 20 13 8*BSC 0 0 0 0* 1.55* * 8.3* 448* 1.4
100 20 13 9 BSIB 0 0 0 0 11 0.1
100 20 13 9*BSC 0 0 0 0* 1.55* * 8.3* 835* 2.7
Total WASTE Volume(Cu.m) 28872066 Tonnage 63518572
Total COAL Volume(Cu.m) 2256046 Tonnage 3496875
ANNEXURE - 2

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SCHEDULE REPORT OF OPENPIT-100 AT THE END OF 1st YEAR
Schedule 20 runs to SAT 31-DEC-05 18:03
==============================================================
Schedule 20 Accumulation values.
Waste Coal/Ore Waste Coal/Ore
Volume+ Tonnage Volume+ Tonnage
(Rehandle) (ROM)(Rehandle) (ROM)
==============================================================
SAT 01-JAN-05 WEATH 546200 546200
TOTALS 546200 546200
TUE 01-FEB-05 WEATH 493336 1039536
TOTALS 493336 1039536
TUE 01-MAR-05 WEATH 539663 1579199
MSOB 98 98
MSC 717 717
BSIB 4623 4623
BSC 2097 2097
TOTALS 544383 2815 1583920 2815
FRI 01-APR-05 WEATH 528578 2107777
TOTALS 528578 2112497 2815
SUN 01-MAY-05 WEATH 533340 2641117
MSC 186 903
BSIB 8716 13339
BSC 6249 8346
TOTALS 542056 6435 2654553 9250
WED 01-JUN-05 WEATH 488812 3129929
MSOB 20260 20358
MSC 8419 9322
BSIB 11986 25325
BSC 3232 11578
TOTALS 521058 11651 3175611 20901
FRI 01-JUL-05 WEATH 504615 3634543
MSOB 27851 48209
BSIB 7470 32795
BSC 9709 21287
TOTALS 539937 9709 3715547 30610
MON 01-AUG-05 WEATH 179353 3813896
MSOB 252589 300798
MSC 32176 41499
BSIB 80009 112804
BSC 20905 42192
TOTALS 511951 53081 4227498 83691
THU 01-SEP-05 WEATH 158188 3972084
MSOB 177557 478356
MSC 41519 83017
BSIB 137889 250693
BSC 43639 85831
TOTALS 473634 85157 4701133 168849
SAT 01-OCT-05 WEATH 510335 4482420
MSOB 7549 485905
MSC 10134 93152
BSIB 19993 270687
BSC 2772 88604
TOTALS 537878 12907 5239011 181755
TUE 01-NOV-05 WEATH 295805 4778225
MSOB 131534 617439
MSC 33785 126936
BSIB 64581 335268
BSC 23038 111642
TOTALS 491921 56823 5730931 238578
THU 01-DEC-05 WEATH 352281 5130505
MSOB 60312 677751
MSC 25924 152860
BSIB 89739 425007
BSC 35294 146936
TOTALS 502332 61218 6233263 299796





Annexure - 3

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TRUCK FLEET REQUIREMENT

-------------------------------------------
MATERIAL PARAMETERS
-------------------
SWELL FACTOR 1.20
INSITU DENSITY 2.200

SHOVEL PARAMETERS
-----------------
BUCKET CUBIC CAPACITY 2.80
BUCKET FILL FACTOR 1.00
BUCKET LOADS PER TRUCK 4.87
SAY 5.0
SPOT TIME 0.50
SHOVEL CYCLE TIME 0.67
TRUCK LOAD TIME 3.80
SHOVEL AVAILABILITY % 100.0
SHOVEL HOURS PER DAY 24.0

TRUCK PARAMETERS
----------------
TRUCK LOAD BY WEIGHT 25.0
TRUCK CUBIC LOAD 13.64
TRUCK LOAD TIME 3.80
TRUCK DUMP TIME 0.50
TRUCK HAUL AND RETURN TIME 10.68
TRUCK CYCLE TIME (MINUTES) 14.98
TRUCK AVAILABILITY % 100.0
EST. MIN TRUCK FLEET REQUIRED 3.94
SAY 4
BANK VOLUME PER TRUCK HOUR 46
-------------------------------------------


TRUCK PRODUCTIVITY
-------------------------------------------
TRUCKS PRODUCTION PRODUCTION
(BANK VOL/HR) (BANK VOL/DAY)
-------------------------------------------
1 46 1093
2 91 2185
3 137 3278
4 179 4306
-------------------------------------------



*****

Annexure - 4