MIINING INDUSTRY

Presented by:
Content

 Overview of the Mining Industry

 Operational Challenges in Mining
 Strategies for Improving Mining Operations
 Case Study: Enhancing Productivity and Safety
 Mining Industry

Overview of Mining industry

Mining is the process of extracting valuable minerals or geological materials from the earth, which cannot be cultivated through agricultural methods
or synthesized in a laboratory. As one of the oldest industries in the world, mining has played a crucial role in human development and economic
growth.

Historical Context
• Ancient
Origins: Mining dates back to prehistoric times when early humans extracted metals like copper and iron, as
well as fuel minerals such as coal. These materials were essential for tool-making, construction, and energy production.
• Evolution: Over centuries, mining techniques have evolved from basic methods to advanced technologies that
enhance efficiency and safety.
The industry produces a wide variety of Product, including
• Precious Metals: Gold and silver.
• Base Metals: Copper, nickel, iron, and aluminium.
• Energy Minerals: Coal and petroleum.
Economic Significance
• Manufacturing Supply Chain: The minerals extracted through mining are crucial for manufacturing thousands of goods, including cars,
electronics (like computers), machinery, and infrastructure components .
• Energy Production: Mining is vital for energy supply; for instance, in India, over 45% of electricity is generated from coal.
 This highlights the industry's role in meeting national energy represents
Mining is broadly done by two methods- Underground Mining and Open
Cast or Surface Mining

Underground Mining:
Underground mining involves extracting minerals and ores from below the earth's surface. It is used when mineral
deposits are located deep within the earth and cannot be economically extracted using surface methods. E.g
Room and Pillar Mining,Longwall Mining,Cut and Fill Mining etc.
Surface Mining:
Surface mining involves removing soil and rock layers (overburden) to access mineral deposits near the earth's
surface. It is typically more cost-effective than underground mining for shallow deposits.
Mining Cycle:

1). Exploration:
o Site Identification: Geological surveys and studies are conducted to identify potential mining sites.
o Sampling: Core samples are taken to analyze the quality and quantity of minerals.
o Feasibility Studies: Assess economic viability, environmental impact, and technical considerations.
 2). Development:
o Planning: Detailed planning for the mine layout, extraction methods, and logistics.
o Permitting: Obtaining necessary permits and licenses from regulatory bodies.
o Infrastructure Development: Constructing access roads, facilities, and utilities (water, power).
3) . Mining Operations:

o Extraction: The actual process of removing minerals or ores using chosen methods (e.g., surface or underground mining).
o Hauling: Transporting extracted materials to processing sites.
4) . Processing:

o Crushing and Grinding: Reducing the size of ore for easier extraction of valuable minerals.
o Concentration: Using physical or chemical processes to separate valuable minerals from waste.
5) . Reclamation and Closure:

o Land Rehabilitation: Restoring mined land to its natural state or repurposing it for other uses.
o Monitoring: Ongoing assessment of environmental impacts and site stability.
o Closure Plan: A detailed plan for safely closing the mine and mitigating future impacts.
In all of the steps of mining, there are several operational problems involved
Operational Activities/Processes:
• Exploration and Site Assessment:
 Geologic surveys, sampling, and feasibility studies.

• Extraction Processes:
Techniques for surface and underground mining.

When choosing a mining method for mineral extraction, several critical factors come into play.

Size, shape, and depth of the deposit.

Geologic structure and geo-mechanical conditions.

Scale of operation and productivity

Requirement of capital

Ore recoveries and profitability

Operational Safety.

Environmental impacts - during and after mining Reclamation and restoration requirements and associated Cost of mining
Surface Mining Methods are generally preferred for deposits close to the surface with relatively uniform geology. UG Mining Methods
are preferred for deeper deposits, and geological and mineralogical characteristics requiring selective extraction. Other conditions equal,
surface mining is normally preferable, because of lower development costs, quicker start up time, higher productivity and lower accident
rates.
Choosing better mining method according to these factor will lead to better productivity and safety.
Lots of operation are involved in this extraction process.optimizing these processes will lead to better
productivity
If we talk about coal extraction process after overburden removal, steps involved in this process is
If we are doing this by drilling and blasting technology
Steps:

1) Drilling
2) Charging the hole with explosives
3) Blasting(Fragmentation)
4) Loading
5) Transportation
6) Dumping
We can make here a process map also
 In underground mining method,several operations involved in extraction of mineral
1) Development of mine: in this process shaft(underground opening) is created, several others thing necessary for
underground mining method made,development of panel according to ug mining methods.
2) Cutting of Mineral
3) Loading of Mineral

4) Transportation by belt conveyor/LHD truck to opening made for extraction

5) Transport to surface by Rope Haulage

6) Transport to dumping location

7) Dumping

Choosing the location for a mine shaft is a critical decision that impacts the overall efficiency, safety, and cost of mining
operations. Here are the key factors to consider when selecting a shaft location:
1. Geological Considerations

• Proximity to Ore Body: The shaft should be close to the mineral deposit to minimize transportation distances.
 • Rock Quality: Assess the rock type and stability, as weaker rocks may require more support and reinforcement.
2. Hydrology

• Groundwater Levels: Evaluate the depth and flow of groundwater to prevent flooding and ensure safe operations.
• Water Management: Consider how to manage water ingress effectively.
3. Access and Transportation

• Surface Access: Ensure easy access for construction and transportation of materials and equipment.
• Transport Routes: Proximity to existing roads or railroads for efficient material transport.
4. Safety

• Emergency Access: Ensure the location allows for quick evacuation in emergencies.
• Risk of Natural Hazards: Assess the likelihood of earthquakes, landslides, or other hazards.
5. Environmental Impact

• Minimize Disturbance: Choose a location that reduces impact on local ecosystems and wildlife.
• Compliance with Regulations: Ensure the site meets environmental regulations and permits.
6). Economic Factors

• Cost of Construction: Consider the costs associated with shaft construction, including
infrastructure needs.
• Operational Efficiency: Location should enhance the overall efficiency of mining
operations
7. Community and Social Considerations

• Proximity to Communities: Assess the impact on local communities, including potential displacement or disruption.
• Community Engagement: Involve local stakeholders in the decision-making process.
8. Geographical Features

• Topography: Evaluate the land's slope and stability to ensure safe construction and operation.
• Existing Structures: Avoid areas with significant infrastructure that could complicate operations.
9. Mining Method

• Type of Mining: Different mining methods (e.g., shaft mining vs. block caving) may dictate the best location for the shaft.
Choosing a shaft location requires a comprehensive evaluation of geological, environmental, safety, and economic
factors. A well-chosen location can enhance operational efficiency and reduce risks, contributing to the success of the
mining operation.
• Processing:
Crushing, grinding, and concentration of ores.

Environmental considerations in processing.

After the extraction of ore it is transported to processing mill for processing of ore after that it becomes completely ready for
use/sale.

• Logistics and Supply Chain Management:

Transportation of raw materials to processing plants and markets.
Inventory management and demand forecasting.

• Health, Safety, and Environmental Management:

Safety protocols and risk management.

Environmental impact assessments and sustainability practices

Solving one operational problem
There are lot of operational problems in mining but most important and necessary problem is that which is associated with safety
because Mining is a hazardous profession associated with high level of accidents and injuries
►According to the Directorate General of Mines Safety report of accident statistics, there were 51 fatalities, 120 serious injuries in
the year of 2019 in Indian coal mines and 40 fatalities, 38 serious injuries in the year 2019 in metal mines.
On an average, there are 62 fatal, 348 serious accidents in coal mines and 41 fatal, 75 serious accidents in metal mines over last
Ten Years (2010-2019).
►The average death rate per 1000 persons employed per year is 0.15 and that of serious injury rate is 0.35 in coal mines; death
rate is 0.22 and serious injury rate is 0.25 in metal mines.

Gas,Dust Other causes Fall of roof

1.75% 5.26% Fall of sides
Fall of object 1.75%
3.50%
Rope haulages
1.75%
Fall of person Dumpers
7.02% 19.30%
Electricity
Truck tanker
7.02%
etc.
Other 12.28%
Explosives Machinery
3.50% 19.30%
Fig.1 Cause-wise distribution of fatal accidents in coal mines during 2018
 Fig. 3 Cause-wise distribution of fatal accidents in non-coal mines during 2018

By Data we can see thar a major portion of fatality is happening due to dumper and truck accident.so we have to manage the
dumper and other machinery effectively so that accident can be prevented.and it will also help in increasing productivity.
By implementing fleet management in mining, companies can reduce costs, improve safety and compliance, and optimize the
productivity of both equipment and personnel. This leads to a more sustainable and profitable operation.
So their are several operational strategic technique which can be applied.
1) Fixed Truck Allocation:

At the beginning of each shift, a set of trucks is assigned to specific transportation routes.
Allocation is based on various criteria, including production requirements and the availability of trucks in the fleet,
Trucks remain locked to their designated paths throughout the shift period.
Path assignments are typically static unless there is a breakdown or a critical event occurs.
This method provides stability but lacks adaptability to changing conditions.
Allocation decisions are influenced by factors such as production needs and the availability of trucks.
The criteria for assigning trucks to specific paths aim to optimize efficiency and resource utilization
The fixed truck allocation method serves as a foundational approach for evaluating the performance of other algorithms and
operational strategies.
2) Flexible Truck Allocation

Flexible truck allocation involves assigning a number of available trucks in the fleet to a specific working shovel at the beginning
of the shift.
Unlike traditional allocation methods, these trucks are not dedicated to a single shovel or route during the shift.
Instead, they receive new assignments from the dispatching system after loading at shovels and tipping at dumping
destinations.
 Flexible truck allocation has been shown to significantly improve the productivity of mining operations.
It has been reported a 13% increase in production at the Bougainville Copper Mine through the use of flexible truck allocation.
TheBarrick Goldstrike Gold mine experienced a 1015% improvement in productivity and a 10% growthin iron ore production
was observed.

As for safety Several operational technique can be applied

Request and Grant System:

Permission control divides the route into sections, allowing only one dump truck at a time to drive on each section.

Dump trucks can drive through their current permitted section without continuous communication with the central control system.

When approaching the end of a section, the truck sends a request to the central control system for permission to enter the next
section.
If permission is granted, the truck continues its route; otherwise, access is denied, preventing potential collisions
Example Scenario
• Dump truck A already has permission, preventing dump truck B from entering, avoiding collisions.

Fleet management system works on some principle that is

a.) Shortest Path Identification:

The first sub-problem focuses on finding the shortest paths that connect all the sources
b.) Optimal Material Production:

In the second stage, the goal is to determine the best possible amount of material to be produced for each identified path.

We have a scenario of a mine layout in which there are 4 Shovel,3 Dump location where we have to dump materials and we have 10
dumpers.
Their scenario are given,

Distances between Shovels and Dump Places:

- Shovel 1: 3 km to Dump 1, 5 km to Dump 2, 4 km to Dump 3

- Shovel 2: 2 km to Dump 1, 6 km to Dump 2, 5 km to Dump 3
- Shovel 3: 4 km to Dump 1, 3 km to Dump 2, 2 km to Dump 3
- Shovel 4: 5 km to Dump 1, 4 km to Dump 2, 3 km to Dump 3
Dumpers' Travel Speeds:*

- Average speed: 30 km/h

Step-by-Step Plan:
1. Mapping Travel Time:
- Shovel 1 to Dump 1: 3km/30km/hr=6min
- Shovel 1 to Dump 2: 5km/30km/hr=10min
- Shovel 1 to Dump 3: 4km/30km/hr=8min
- Shovel 2 to Dump 1: 2km/30km/hr=4min
- Shovel 2 to Dump 2: 6km/30km/hr=12min
- Shovel 2 to Dump 3: 5km/30km/hr=10min
- Shovel 3 to Dump 1: 4km/30km/hr=8min
- Shovel 3 to Dump 2: 3km/30km/hr=6min
- Shovel 3 to Dump 3: 2km/30km/hr=4min
- Shovel 4 to Dump 1: 5km/30km/hr=10min
- Shovel 4 to Dump 2: 4km/30km/hr=8min
- Shovel 4 to Dump 3: 3km/30km/hr=6min
 Total Cycle Time for Each Shovel-Dump Pair

For each shovel-dump combination:

• Shovel 1:

Dump 1: 10(loading/unloading)+6*2(Round trip)=22 min

Dump 2: 10+10*2=30 min Dump 3: 10+8*2=26 min

• Shovel 2:

Dump 1: 10+4*2=18 min Dump 2: 10+12*2=34 min Dump 3: 10+10*2=30 min

• Shovel 3:

Dump 1: 10+8*2=26 min Dump 2: 10+6*2=22 min Dump 3: 10+4*2=18 min

• Shovel 4:

Dump 1: 10+10*2=30 min Dump 2: 10+8*2=26 min Dump 3: 10+6*2=22 min Balancing Dumper

Allocation
To minimize the idle time for the dumpers and shovels, we need to assign dumpers in such a way that:
Shorter cycle times have more dumpers assigned to them to keep the shovels working continuously.
We avoid overloading any single dump or shovel with too many dumpers.
Given that we have 10 dumpers, let’s prioritize shovels with shorter cycle times, so they don’t sit idle while waiting for dumpers.
Dumper Allocation Strategy:

1. Shovel 2 (Shortest Cycle Time at Dump 1:18 minutes):

o Assign 3 dumpers here, as it has the shortest cycle time, and we want to maximize productivity.
o With 3 dumpers, each dumper can complete its 18-minute cycle, and the shovel will rarely sit idle.
2. Shovel 3 (Next Shortest Cycle Time at Dump 3: 18 minutes):
o Assign 3 dumpers here as well, since this shovel also has a short cycle time.
o Each dumper can complete the 18-minute cycle and keep the shovel productive.
3. Shovel 1 (Third Shortest Cycle Time at Dump 1: 22 minutes):
o Assign 2 dumpers here to handle the 22-minute cycle. While the cycle time is slightly longer,
 two dumpers should be able to cycle in and out efficiently.
4. Shovel 4 (Fourth Shortest Cycle Time at Dump 3: 22 minutes):
o Assign 2 dumpers here to handle the 32-minute cycle, balancing out the remaining resources.
Let’s now calculate the productivity, i.e., the number of cycles a dumper can complete in an hour for each shovel-dump pair:

No. of cycles per hour=60/cycle time(min)

For n dumpers it will be n*60/cycle time(min)

Total Cycles Per Hour:

• Shovel 2 (3 dumpers): 3*60/18=10 cycles/hr

• Shovel 3 (3 dumpers): 3*60/18=10 cycles/hr
• Shovel 1 (2 dumpers): 2*60/22=5.45 cycles/hr
• Shovel 4 (2 dumpers): 2*60/22=5.45 cycles/hr
Total Dumper Cycles per Hour:
10+10+5.45+5.45=30.9 cycles/hr

Optimal Dispatching: This allocation keeps all the shovels engaged without excessive idle times for either the shovels or the dumpers.
Minimized Idle Time: Since the shortest cycle times are prioritized with more dumpers, this ensures maximum utilization of both the
shovels and dumpers.