JOURNAL OF RESOURCE MANAGEMENT AND TECHNOLOGY ISSN NO: 0745-6999

EVALUATION OF RIPPER AND DOZER IN METALLIC AND

NON METALLIC SURFACE MINES
1
K GOPINATH, 2Mr.K.MANOJ, 3Mr. K.S. RAMBABU
1
M.Tech Student, 2,3Assistant Professor
Department of Mechanical Engineering
KAKINADA INSTITUTE OF TECHNOLOGICAL SCIENCES, Ramachandrapuram

ABSTRACT When this idea made its way to Europe, new

Drilling and blasting activities are needed in open cast
mining in order to recover ore or coal while also
freeing the strata. Drilling and blasting activities are
linked to a variety of issues, including the creation of
dust, the evolution of hazardous gases, ground
vibrations, crack development, and noise production.
As a consequence, these operations aren't seen as
environmentally beneficial. As a result, we're looking
for a blast-free mining technique. These procedures
are also excessively expensive since they need a lot of
equipment and labour. To save the environment, blast-
free mining is the era's need. Ripper dozer has been
identified as a potential option as a consequence of
different types of investigations and research. Ripper
is mostly used for the removal of overburden. It not
only lowers the number of machines on the job, but it
also provides a more effective solution to the
difficulties that drilling and blasting operations may
cause. As a consequence, thorough rippability
measurement of the stratum with the current
equipment to be installed must be done correctly
before installing any ripper or dozer. The rippability of
rocks is influenced by a number of factors. The
relationship between ripper restrictions and
productivity is investigated. Rippers are used in mines
to account for all of these limitations.
1. INTRODUCTION
LAYOUT:
It has been discovered via different studies and
investigations that mining activities date back
thousands of years. Back in history, the Romans used
hydraulic mining to fracture rocks, but it really took
off when the Chinese developed black powder as an
explosive during the mediaeval era, and the rest is
history.
technologies were brought into play as well. Then, in
the late middle period and the beginning of the modern
age, the development of dynamite accelerated the
speed of mining.
The usage of ammonium nitrate and many other
explosives has miraculously boosted the amount of
food produced these days.
However, the correct use of drilling patterns and the
positioning of holes with the appropriate quantity of
explosives ensures the effectiveness of rock breaking.
The development of different blasting and drilling
methods was also linked with the advancement of
transportation and loading procedures, which allowed
for greater production rates to be achieved. With such
a change in technology, we can see open cast mining
techniques being used to mine to greater depths in the
near future, allowing for deeper mining. As a
consequence, we can see that open cast mining
accounts for 70% of the overall mining output in the
globe. It is necessary to conduct drilling and blast
operations during the open cast method of ore mining
in order to achieve a high level of output. However, it
is well recognised that these activities have a variety
of adverse impacts on the environment. As a result, in
today's environmentally aware society, there is a need
for alternative technologies for explosion-free,
environmentally friendly, and environmentally
friendly mining. The combination of a ripper and a
dozer may provide a powerful and appropriate
response to today's needs. It not only minimises the
negative impact on the environment, but it also lowers
the cost of manufacturing by reducing the mining
activities.

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Objective:
The only purpose of this research is to examine the
usability and performance of a ripper-dozer
combination in coal and metal opencast mines, as well
as to propose some contemporary advancements.
Research Approach:
I. In order to identify the different limitations and their
impact on the performance of the ripper-dozer
combination, a significant quantity of literature
research has been conducted, as shown in Figure 1.
II. C++ applications are implemented in order to save
computation time and update the research method.
III. A comparison of the many Ripper dozers now
available on the market, as well as their specifications,
has been given.
IV. Two distinct case studies have been carried out in
order to investigate the performance and application of
the ripper dozer in question. In this study, case studies
from the Panchpatmali mines (bauxite), the National
Aluminium and Limestone Corporation of India, the
Damanjodi and Talabira coal OCP, and HINDALCO
were examined.
V. This thesis also includes a discussion of recent
technological.
2. LITERATURE REVIEW
Contextual:
The ripping-dozer combo first appeared in the late
1950s. Previously, it was primarily used for the
removal of overburden. However, because to
advancements in its structural design, it is currently
being used for the extraction of ores as well. A
bulldozer's ripper is used to cut, break, or remove rock
with the assistance of tynes that are connected to the
rear side of the machine. The Tyne is dropped into the
rock or soil to be removed, and after it has penetrated
deep into the strata, the bulldozer is pushed ahead in
order to take the dirt or rock from the ground. It
operates in the same manner as a plough in terms of
technique. Ripping operations are often preferred over
drilling and blasting operations for relatively soft
rocks because they are less disruptive. The increasing
global concern over the preservation of ecosystems, as
well as the execution of different regulations, has
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ISSN NO: 0745-6999
prompted the development of solutions such as the
ripper-dozer combo. It not only helps to decrease air,
noise, and dust pollution, but it also helps to eliminate
ground vibration, which is a significant danger to the
preservation of surface characteristics. Due to the
advancements in science and technology, the usage of
high-capacity rippers with high power has made it
feasible to utilise them as an alternative to traditional
drilling and blasting methods. Due to the fact that it
employs the same method that ancient people
employed for plough pulled by oxen in order to
cultivate crops, we may date the invention of rippers
to about 312 B.C. As time progressed, many
advancements were achieved, and now we can see that
we have rippers that can lift up to 1000 tonnes and
operate on a tractor with a horsepower of 1000
horsepower.
Advantages of ripping operation:
An increase in both output and productivity is
achieved when we utilise the ripper-dozer combo since
the job is never stopped. There is no need for drilling
holes, charging the holes, and then conducting blasting
operations thereafter. In contrast to this, the tearing
process continues unbroken. As a consequence, the
amount of idle time at work is reduced. There is no
requirement for the moving of equipment that is
needed in the blasting process to occur. As a result, as
the amount of time spent working rises, so does the
amount of output and productivity. Extraction of Rock
with the Required Size: The size of the rock removed
during a blasting operation may vary greatly, ranging
from boulder size to a few millimetres in size. On the
other hand, by selecting the appropriate size of the
ripping machine, we may get the required size of rock
in the quarry.
Lowered power: As a result of the decrease in the
number of machines, the amount of power needed to
operate them is also reduced.
Profitable: Because ripping requires a less quantity of
equipment, the cost is cheaper because there are no
costs associated with operation, labour, or machine
maintenance.
The different kinds of Rippers available: (P. K Panda
and S. K Misra , 1989)
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The following are the many types of rippers and dozers
available on the market, which are categorised
according to their working methodology:
Hinge Kind Of Ripper Parallelogram Kind Of Ripper
Adjustable Parallelogram Kind Of Ripper Adjustable
Radial Kind Of Ripper
Calculation for rippability of a rock
Table 2.1: Distinct researchers take into account a variety of different factors.
The following are the factors that influence the
rippability of rock:
• Ripping type: Sedimentary rocks are simple to
tear, while igneous and metamorphic rocks are
more challenging.
• Rock fragility and crystalline structure.
• Fracture plane that is well-known.
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In order to choose the most suitable ripper, we must
first determine the rippability of the rock being
worked. Various studies have determined that the
rippability of rock is dependent on a variety of
variables. In the table below, it has been shown which
researcher is responsible for whatever parameter in the
study
• Moisture content is present:
• Grain size: the larger the grain size, the better it is
for tearing.
• Combination of several types of rock.
• Energy that is specific.
• Compressive strength, tensile strength, shear
strength, and other physical characteristics of stratum
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Fig.2.2: Types of rock extraction based on stratum conditions.

Table 2.2: Extent of ripping, taking different features into consideration (Rock excavation techniques, MnE-415 notes,
university of Arizuana mining and geological engineering.)

Fig.2.6: Relationship for seismic velocity and ripping conditions to ripping (Basis: Caterpillar, 2008).

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JOURNAL OF RESOURCE MANAGEMENT AND TECHNOLOGY ISSN NO: 0745-6999

3.VARIOUS RIPPER-DOZER SPECIFICATIONS AND THEIR APPLICABILITY

Table 3.1 shows the specifications of several ripper dozers available in India from various manufacturers.

Ripping is influenced by a variety of variables, however there is a connection between the quantity of production and
the ease of ripping, as seen below:

Table 3.2: Relationship between ease of ripping and production ( by Fiona MacGregor)

4. FIELD STUDY 1: PACHPATMALI BAUXITE
MINES, N.A.L.C.O
4.1. Introduction:
National Aluminum Company Limited (N.A.L.C.O)
manages the Panchpatmali bauxite mine, which
produces 4.8 million tones of bauxite ore and 1.6
million tonnes of overburden. Rippers of a large size
have been used as an alternative to drilling and
blasting. The deposits discovered here are
Precambrian in age. Hard ferruginous laterite with a
thickness ranging from 0 to 3.5 m makes up the
overburden, which is followed by a layer with a
thickness ranging from 10 to 35 m and an average

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thickness of 14 m. According to NGRI Hyderabad's
study of seismic wave velocity of various formations,
it varies from 1100 m/s to 2600 m/s, with more than
80% of deposits falling within the 1100 -1300 m/s
velocity range and 15% falling between the 1300 to
2600 m/s velocity range and above.
It demonstrates the deposit's suitability for efficient
and cost-effective production ripping, and it allowed
the engineers to choose suitable equipment for the
different sizes of rocks from among the current
rippers.
The main mineral constituents of Khondalites and
Chanockite rocks include granet, sillimanite
Corundum feldspar quartz, and also opaque ore
minerals limonite and graphite.
Slopes of less than 10%, although steeper across 2/5
of the deposit, and a highly uneven contact between
ore and bottom provide little relief.
Mining techniques
Mining is carried out in three stages at the same time:
Excavation of overburden: Overburden is mined in
two phases and is made up of top soil and laterite. Top
soil is dug and transported ahead of laterite, then stored
separately for use in reclaimed area plantations. The
whole quantity of laterite extracted is just on one
bench above bauxite, with a lead of 75 metres.
Because there is less overburden than ore and the rock
is relatively soft, it may be broken by tearing. Ripping
is linked to blasting, which is used to create tougher
Fig 4.1.Technique for reclamation of mined area of the mine
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rock formations. After blasting or tearing the OB, the
mineralized top is cleaned with a wheel loader and
dozer. With the assistance of a loader, the overburden
is subsequently placed into a 50/55 tonne dumper. It is
then transported to a location where overburden is
needed for reclamation.
Bauxite excavation: Bauxite mining is now done in
two stages: top bench mining and bottom bauxite
mining. Drilling and blasting are used to dig the upper
benches, which have an average height of 8 metres and
drill holes that are 150 mm in diameter and bored by
DTH drills. To loosen the ore, it is charged with indo–
boost, indo–gel, and blasted. The 8.7 m3 wheel loader
loads the blasted material into 50/55 tonne dumpers,
which transport it to the crusher. For entire bauxite
extraction, the final bench of bauxite is selectively
mined using a back hoe. Bauxite ore is crushed using
a double roll toothed crusher until it reaches a size of
150 mm, after which it is transported. It is transported
to a recycling facility by a 14.6-kilometer-long belt
conveyor.
Reclamation of the removed area: Reclamation is
carried out at the same time as the chosen mining
technique, trench mining. When the bauxite extraction
is finished, the land is cleared for backfilling with
overburden, which consists of rich soil and laterite that
was previously mined. Laterite is delivered to the
lowest level, with a thin layer of soil remaining on top
for planting operations. In the reclaimed area,
reservoirs and sumps are built to collect water and
avoid land deterioration due to soil erosion.
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Table 4.1.2: I.I.T Kharagpur is researching the physico-mechanical characteristics of laterite and bauxite.

This test revealed that the ore from Panchpatmali mine is very susceptible to tearing

Figure 4.1.2 Komatsu D-475 working the mine

All specs for all rippers and dozers may be found in the table of specifications.

On the basis of cost, drilling and blasting are compared to tearing.

Cost of drilling and blasting per tonne extracted

The average drilling operation per day is 560 metres.

So, because we had two working shifts of 280m each, we used three drilling machines and three operators to operate
them, and the actual working hour in a shift was four hours, interest for one drill machine was Rs. 4417.8469,
depreciation cost of machine was Rs. 6126.25, and rear and management expenditures were Rs. 5416.667.

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Table 4.1.3 Calculation for expenditure for drilling per MT

5. RECENT DEVELOPMENTS IN THE FIELD • Maximization of the use of the machine.

OF RIPPER DOZER
• Improved overall visibility for the operator.
5.1 Remote operation of ripper and dozer: (Remote
• Improved working conditions for the operator in
control technologies Pv.t Ltd, Australia)
terms of ergonomics.
Remote Control Technologies is the sole company
In between manufacturing cycles, there is less idle
responsible for the remotization of the ripper and the
time.
dozer. This firm developed several models for
Caterpillar, including the D5N, D8T, D9H, D10, The ability to maintain tighter control over key
D10N, D10R, D11N, D11R Series 1, 2, and 3, as well machine tolerances.
as the KOMATSU D475, D572-A2, D575A, D575A-
3, and the D275AX. When RCT installed the first • It is possible to do dangerous machine operations in
remote control system for a CAT D11NinPNG dozer a safe manner.
in 1989, it was a world first. RCT was the first
5.2 Mine APS Dozer
company in the world to remotely operate a CAT D8T
dozer in 2006. It serves as a model for the successful use of
contemporary technologies. It is a GPS+GLONASS
5.1.1 The following are some of the benefits of using
appliance monitoring solution for dozers, which
a remote control:
allows for faster, safer, and more productive operation
• Prevents repeated stress injuries from occurring. while reducing costs. Excellent accuracies A

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GPS+GLONASS surveillance system enables for
precise dozing planning without the necessity for
rechecking or correcting.
5.2.1 Features:
• Represent the machine location in 3D accurately in
comparison with the CAD model.
Compact and versatile GPS+GLONASS receivers to
balance investments and application requirements. •
Open system technologies such as Microsoft
Windows, SQL, XML, NMEA, and Share point
services are available.
• Operator interface with a touch screen that is simple
to use.
• The operator has the option of working on the design
surface or on offsets.
• Allow for several user selected surfaces to be
included inside a single file.
• Diagnostics of the onboard system.
The use of fixed hazard and mobile equipment
proximity alerts is recommended.
• Optional ripper sensor is available.
• An optional blade guiding sensor is available.
• Communication interface that is open to all
communication systems, including 3G cellular,
802.11x wireless, mesh, and others.
• Off-board and on-board production reporting options
by machine, area, group, or operator, including:
volumes, push lengths, cycles, re handle, idle vs. push
vs. ripping, delays, export DTM of ‘as constructed'
surface, and a variety of other parameters.
5.2.2 BENEFITS OF THE SYSTEM:
• It is feasible to mine selectively, which will result in
higher quality ore.
• Fixed danger and proximity alerts have been
implemented to increase safety.
• Increased efficiency while also reducing mistakes.
• Produces outcomes in less time and with fewer
passes.
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ISSN NO: 0745-6999
• Decrease the amount of rework caused by over- or
undercutting or underfilling.
• Significantly decrease reliance on survey and grade-
checking data collection.
• Machine-based production reporting eliminates
human error and increases the timeliness and quality
of management information over time.
6. CONCLUSION
• As a result of the widespread use of reformed
technology, ripping has risen in importance relative to
drilling and blasting as a primary activity.
• Its major drawback is that it is not suitable for use on
very hard rocks. As a result, it may be linked with
drilling and blasting in order to provide a more
satisfactory answer.
• Based on the above results, we may infer that it is a
cost-effective, safe, and economical operation.
• It has the potential to be used as a blast-free mining
system.
• Because ripping has no negative impact on the
environment, we can preserve the ecosystem as well
as animal habitats by using it.
In addition, since the retrieved ores or overburden are
homogeneous in size, there is no need for additional
operations such as secondary blasting.
• The development of methods and equipment has the
potential to provide a final solution for drilling and
blasting operations.
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Abd. Hamid; Mohd Khairolden ndGhani.“Rippability
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production rate”,construction industry research
achievement international conference (CIRAIC 2009).
Pp-3- 5.
ii. Panda P.K ; Misra S.K. “Ripping an aid to primary
mining system a N.A.L.C.O rdexperience”, 3 national
conference on surface mining, 1989.
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iii. Samal Subhrakanta ; Dash Ashish ; Murthy
V.M.S.R ; Mohanty P.R. “ Ripping –an excavation
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Abd. Hamid; Mohd Khairolden nd Ghani.
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(CIRAIC2009). Pg-3- 5.

xi. Panda P.K ; Misra S.K. “Ripping an aid to primary

mining system a NALCO rdexperience”, 3 national
conference on surface mining, 1989.

xii. Samal Subhrakanta; Dash Ashish; Murthy

V.M.S.R; Mohanty P.R. “Ripping –an excavation
technique of future promise”, ISM Dhanbad.

xiii. Basarir H.; Karpuz C.; Tutluoglu L. (2007). “A

fuzzy logic based rippability classification system”.
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