kusmunda mine traffic simulation simulation
DESCRIPTION
The Kusmunda Mine is the second largest Coal mine in India with an annual capacity of 35 million tons of coal. This project involved simulation of dumper truck traffic congestion using FlexSim simulation software.TRANSCRIPT
Mine Traffic SimulationKusmunda Mine
SECLMano KanthanathanCommercial Consultancy Services [email protected] 16, 2014
Objectives
• Build a 3D Traffic Simulation Model for the Kusmunda Open Cast Mine to:
– Analyze traffic congestion at various intersection points
– Identify vehicle bottlenecks at Weigh stations and Load zones
– Model scenarios for traffic for varying truck numbers, truck speeds, road lanes, safety distance, capacities and loading times – Base and 4 Scenarios
– Model scenarios for different calendar time periods (days, weeks, months or year) for mine throughput in tons for Coal and Waste for each route
Commercial Consultancy Services – Bangalore, India
• Vehicles waiting at – Intersections
– Load zones
– Weigh bridges
• Mine output for Coal and OB• Scenario Comparison
Traffic & Mine Performance Metrics
Commercial Consultancy Services – Bangalore, India
Safety distance and intersection rules enforced in all truck movements
• 2d CAD layout for Kusmunda mine with all intersections, load zones, dump zones, weigh bridges marked
• Schedule of number of trucks entering each route• Route details from parking lot to load zones, dump zones and break areas• Safety distance• Truck speeds for different gradients• Loading and Weighing process times• Intersection rules• Truck capacities• Shift timings
Mine Model Input Parameters
Commercial Consultancy Services – Bangalore, India
Mine Model Logic Development
Custom logic developed for Traffic simulation for:– Intersection logic for right of way, priority and stopping distance– Importing road coordinates in 3d space and building 3d road layout from 2d CAD file– Safety distance enforcement– Road surface below road paths– Truck movements for loading, unloading, driver breaks and weighing– Truck scheduler– Speed control of trucks based on differing gradients– Coal and OB output graphs– Intersection, Weigh bridge and loading congestion graphs
Commercial Consultancy Services – Bangalore, India
Kusmunda Mine Simulation Model
Commercial Consultancy Services – Bangalore, India
• Base Scenario or ‘As Is’ Scenario• Scenario 1
– 50% more SECL vehicles for OB– One more loader– No SMAS OB vehicles
• Scenario 2– 50% more SECL vehicles for OB– One more loader– No SMAS OB vehicles– Two lane roads for OB removal
Scenarios Examined for Kusmunda Mine
Commercial Consultancy Services – Bangalore, India
• Scenario 3– 50% more Contractual Vehicles for Coal & OB
– No SECL vehicles
– One more loader in each route for Contractual vehicles
• Scenario 4– 50% more Contractual and SECL Vehicles for Coal & OB
– Sub scenario 1 – One more loader in each route
– Sub scenario 2 – No change in loader
Scenarios Examined for Kusmunda Mine – contd.
Commercial Consultancy Services – Bangalore, India
Commercial Consultancy Services – Bangalore, India
TOTAL SMAS OBSMAS COAL ESM1 ESM2
MAHAVIR COAL
ROAD SELL BCM AKT SECL LOADER
BASE SCENARIO 272 45 25 60 10 14 55 10 15 38 NO CHANGE
SCENARIO 1 240 0 25 60 10 14 55 10 15 51 ONE MORE LOADER
SCENARIO 2 240 0 25 60 10 14 55 10 15 51 ONE MORE LOADER
SCENARIO 3 351 68 38 90 15 21 83 15 23 0ONE MORE LOADER IN ALL CONTRACT ROUTES
PERCENT INCREASE 29%
SCENARIO 4A and 4B 408 68 38 90 15 21 83 15 23 57
ONE MORE LOADER IN ALL CONTRACT AND SECL ROUTES
PERCENT INCREASE 50%
Scenarios – Truck Numbers & Loader
Commercial Consultancy Services – Bangalore, India
Base Scenario
Traffic Congestion – Intersection – Base Scenario
Congestion observed at:– SJ1, SJ19, SJ22 & QJ2 – with average vehicles waiting:
• SJ1 – 35 vehicles• SJ19 – 19 vehicles• SJ22 – 73 vehicles• QJ2 – 14 vehicles
– All intersections marked in layout
If required congestion can also be measured inamount of time each vehicle waits at intersection!
Commercial Consultancy Services – Bangalore, India
Traffic Congestion – Load Zones – Base Scenario
Commercial Consultancy Services – Bangalore, India
Traffic Congestion – Weigh Bridges – Base Scenario
Commercial Consultancy Services – Bangalore, India
Mine Output – Coal – Base Scenario
Commercial Consultancy Services – Bangalore, IndiaTotal Coal Output - yearly estimate is around 20.7 Million tons
Mine Output – OB – Base Scenario
Commercial Consultancy Services – Bangalore, IndiaTotal OB Output yearly estimate is around 23.9 Million tons
Commercial Consultancy Services – Bangalore, India
Scenario 150% more SECL vehicles for OBOne more loaderNo SMAS OB
Traffic Congestion – Intersection – Scenario 1
Congestion observed at:– QJ2 for OB vehicles is 16 vehicles
Commercial Consultancy Services – Bangalore, India
Mine Output – Coal – Scenario 1
Total Coal Output - yearly estimate is around 23 Million tonsCommercial Consultancy Services – Bangalore, India
Mine Output – OB – Scenario 1
Total OB Output yearly estimate is around 27.9 Million tonsCommercial Consultancy Services – Bangalore, India
Commercial Consultancy Services – Bangalore, India
Scenario 250% more SECL vehicles for OBOne more loaderNo SMAS OBTwo lane roads for OB removal
Traffic Congestion – Intersection – Scenario 2
Congestion observed at:– QJ2 intersection for OB for SECL vehicles is 9 vehicles
which is reduced from 16 vehicles because of usinga two lane road
Commercial Consultancy Services – Bangalore, India
Mine Output – OB – Scenario 2
Total OB Output yearly estimate is around 27.3 Million tons – slightly less than Scenario 1Commercial Consultancy Services – Bangalore, India
Conclusion is that adding a road in a part or section of the mine will not necessarily increase the output of Coal or OB, as bottlenecks in other sections of the mine will prevent an increase in output from occurring.
Mine Output – Coal – Scenario 2
Total Coal Output - yearly estimate is around 23.2 Million tons – almost same as Scenario 1Commercial Consultancy Services – Bangalore, India
Conclusion is that adding a road in a part or section of the mine will not necessarily increase the output of Coal or OB, as bottlenecks in other sections of the mine will prevent an increase in output from occurring.
Commercial Consultancy Services – Bangalore, India
Scenario 350% more Contractual Vehicles for Coal & OBNo SECL vehiclesOne more loader in each route for Contractual vehicles
Traffic Congestion – Intersection – Scenario 3
Commercial Consultancy Services – Bangalore, India
Congestion increase from Base scenario observed at:– SJ1, SJ19 & SJ22 – with average vehicles waiting:
• SJ1 – 42 vehicles from 35 vehicles• SJ19 – 21 vehicles from 19 vehicles
• SJ22 – 91 vehicles from 73 vehicles
Mine Output – Coal – Scenario 3
Total Coal Output - yearly estimate is around 19.4 Million tonsCommercial Consultancy Services – Bangalore, India
ROADSELL may be limited by traffic
congestion as compared to ESM1
Mine Output – OB – Scenario 3
Total OB Output yearly estimate is around 6.5 Million tonsCommercial Consultancy Services – Bangalore, India
Commercial Consultancy Services – Bangalore, India
Scenario 450% more Contractual and SECL Vehicles for Coal & OBSub scenario 4A – One more loader in each routeSub scenario 4B – No increase in loader
Traffic Congestion – Intersection – Scenario 4A
Commercial Consultancy Services – Bangalore, India
Congestion increase from Base scenario observed at:– SJ1, SJ22 & QJ2 – with average vehicles waiting:
• SJ1 – 59 vehicles from 35 vehicles• SJ22 – 95 vehicles from 73 vehicles
• QJ2 – 19 vehicles from 14 vehicles
Mine Output – Coal – Scenario 4A
Total Coal Output - yearly estimate is around 28.7 Million tonsCommercial Consultancy Services – Bangalore, India
Mine Output – OB – Scenario 4A
Total OB Output yearly estimate is around 32.8 Million tonsCommercial Consultancy Services – Bangalore, India
Traffic Congestion – Intersection – Scenario 4B
Commercial Consultancy Services – Bangalore, India
Congestion increase from Base scenario observed at:– SJ1, SJ22 & QJ2 – with average vehicles waiting:
• SJ1 – 57 vehicles from 35 vehicles• SJ22 – 93 vehicles from 73 vehicles
• QJ2 – 18 vehicles from 14 vehicles
Mine Output – Coal – Scenario 4B
Total Coal Output - yearly estimate is around 28 Million tonsCommercial Consultancy Services – Bangalore, India
Mine Output – OB – Scenario 4B
Total OB Output yearly estimate is around 31.4 Million tonsCommercial Consultancy Services – Bangalore, India
Commercial Consultancy Services – Bangalore, India
Scenario Summary
Annual Output Coal Annual Output OB
Base Scenario 20.7 Million tons 23.8 Million tons
Scenario 1 23 Million tons 27.9 Million tons
Scenario 2 23.2 Million tons 27.3 Million tons
Scenario 3 19.4 Million tons 6.5 Million tons
Scenario 4A 28.7 Million tons 32.8 Million tons
Scenario 4B 28 Million tons 31.4 Million tons
Commercial Consultancy Services – Bangalore, India
Recommendations to Reduce Traffic & Increase Throughput
• Use larger capacity vehicles to increase throughput of every load / unload cycle
• Use larger capacity shovels to reduce loading time
• Consider replacing contract routes, such as ESM2, BCM and AKT with fewer and larger SECL vehicles
• Consider revisions in road layout by reducing the number of intersections
• Examine more scenarios to improve mine strategy
Scenario Development in Mine Traffic
Input Tables for:
1. Truck numbers for each route2. Load and Unload time of trucks3. Differing speeds4. Differing Truck capacities
Input data can be fed directly froma Excel spreadsheet into the KusmundaModel to examine different scenarios
Commercial Consultancy Services – Bangalore, India
Safety with Mine Planning – future scope
• Vehicle fuel consumption rates in FlexSim model
• Truck break downs and repair
• Tire replacement based on kilometers travelled
• Statistics on actual loads carried by trucks for each category – analysis of weight distributions
• Excel input interface for ease of use and create a Web Interface to run the Kusmunda model
• Integrate Kusmunda mine model with SECL data base
• Optimize the mine model using advanced capability in FlexSim called OptQuest
• Add special objects, such as Load zones, Intersections, 3d layout convertor to enable easy build of mine models
Commercial Consultancy Services – Bangalore, India
Queries