Technical and Economical Optimization Of
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Technical and economical optimization of surface mining processes – Development of a data base and a program structure for the computer-based selection and dimensioning of equipment in surface mining operations Dissertation zur Erlangung des Grades eines Doktor-Ingenieurs vorgelegt von M.Sc. Raheb Bagherpour Aus dem Iran Genehmigt von der Fakultät für Energie- und Wirtschaftswissenschaften der Technischen Universität Clausthal Tag der mündlichen Prüfung 17.09.2007 Vorsitzende: Prof.Dr. Heike. Y. Schenk-Mathes Hauptberichterstatter: Prof. Dr.-Ing. habil. H. Tudeshki Berichterstatter: Prof. Dr.-Ing. Oliver Langefeld Contents Contents .........................................................................................................................I Figures List .................................................................................................................. IV Tables List.................................................................................................................... VI 1 Introduction...................................................................................................1 2 Mining Industry Progresses ........................................................................3 2.1 The History of Mining......................................................................................3 2.2 Mining and Mineral Description ......................................................................4 2.3 Mining Technology Progresses.......................................................................5 3 Mineral Industry............................................................................................9 3.1 Mineral Production and Consumption.............................................................9 3.2 Mineral Economics .......................................................................................15 4 Mining Stages and Methods ....................................................................19 4.1 Mining Stages...............................................................................................19 4.2 Exploitation ...................................................................................................19 4.3 Surface Mining..............................................................................................21 5 Mining Costs ...............................................................................................22 5.1 Mining Stages Costs.....................................................................................22 5.2 Mining Operation Cycles and Their Costs ....................................................24 6 Materials Handling......................................................................................27 6.1 Materials Handling Operation .......................................................................27 6.2 Principles of Loading and Excavation...........................................................27 6.3 Selection of Loading Equipments .................................................................29 6.4 Principles of Haulage and Hoisting...............................................................33 6.5 Selection of Haulage and Hoisting Equipments............................................36 6.6 Selection of Materials Handlings Systems in Surface Mining .......................36 7 In-pit Crushing ............................................................................................40 7.1 In-pit Crushing System .................................................................................40 7.2 Mobile Crushers............................................................................................40 7.3 Advantages of Continuous Haulage Methods...............................................41 7.4 Location of Primary Crushers .......................................................................43 8 Cost Estimation in Open Pit Mines ...........................................................51 8.1 Cost Estimation for Operation Cycles...........................................................51 8.2 Cost Estimation for Loading and Haulage Equipments.................................56 I 8.2.1 Cost Estimation for Bucket Wheel Excavators..............................................57 8.2.2 Cost Estimation for Power Shovel-Trucks Fleet ...........................................61 8.2.3 Cost Estimation for Hydraulic Shovel-Trucks Fleet.......................................66 8.2.4 Cost Estimation for Walking and Crawler Draglines .....................................71 8.2.5 Cost Estimation for Belt Conveyors ..............................................................76 8.2.6 Cost Estimation for Aerial Tramway..............................................................79 8.2.7 Cost Estimation for Scrapers ........................................................................82 8.2.8 Cost Estimation for Mobile Crushers ............................................................87 9 Estimation and Calculation of Size and Number of Loading and Haulage Equipments ...................................................................................................93 9.1 Estimation of Size and Number of Loading and Haulage Equipments..........93 9.2 Calculation of Size and Required Number of Loaders..................................93 9.3 Calculation of Size and Required Number of Hydraulic Shovel ....................99 9.4 Calculation of Size and Required Number of Power Shovel.......................102 9.5 Calculation of Size and Required Number of Trucks ..................................108 9.6 Reserve Machines......................................................................................114 9.7 Simultaneous Situation of Loading and Haulage Equipments ....................114 10 Estimation and Calculation of Production Costs for Loading and Haulage Equipments .................................................................................................115 10.1 Estimation of Production Costs for Loading and Haulage Equipments.......115 10.2 Calculation of Production Costs for Loading and Haulage Equipments......115 10.2.1 Capital Costs ..............................................................................................116 10.2.2 Operating Costs..........................................................................................117 10.2.2.1 Energy and Fuel Costs ...............................................................................117 10.2.2.2 Lubrication and Filter Costs ........................................................................119 10.2.2.3 Tire Costs ...................................................................................................119 10.2.2.4 Maintenance and Repair Parts Costs .........................................................119 10.2.2.5 Wear Parts Cost .........................................................................................121 10.2.2.6 Labor Costs ................................................................................................121 10.2.2.7 Total Production Costs ...............................................................................121 11 Conclusion ................................................................................................132 References .................................................................................................................134 Curriculum Vitae........................................................................................................140 II Summary ....................................................................................................................141 Acknowledgement.....................................................................................................143 III Figures List Figure1 Per capita consumption rate of minerals through the life in Germany (with an average assumption of life of 78 years)...............................................9 Figure 2 Estimated amount of ore production in metal mines........................................11 Figure 3 Trend of mineral and waste production in recent 10 years..............................12 Figure 4 Estimated amount of materials handling in surface mines...............................13 Figure 5 World wide explorations (based on active sites) for Precious metals and diamond [34]........................................................................................... 15 Figure 6 World wide explorations (based on active sites) for base metals [34] .............16 Figure 7 World wide explorations (based on active sites) for other minerals [34].......... 16 Figure 8 Distribution of costs for relevant activities of production cycle in open pit mines......................................................................................................25 Figure 9 Distribution of operating costs for relevant activities of production cycle with considering of in-pit crushing in open pit mines......................................26 Figure 10 Distribution of total capital costs in open pit mines ........................................26 Figure 11 A mobile in- pit crusher [54]........................................................................... 40 Figure 12 A semi-mobile in- pit crusher [54] ..................................................................41 Figure 13 The Nett Present Value (NPV) of costs in both systems in different years of life of the mine [60] .............................................................................43