Rahmat Muallim paper CAFEO 32 Myanmar (rangoon)

1

MIDDLE TERM PLANNING OF MINE MATERIAL HANDLING

INTO DETERMINE OPTIMIZATION SCHEDULING

AND SMALL FLEET SCENARIO IN OPEN PIT

(CASE STUDY : BLOK 1A5A1517 PT VALE INDONESIA

BAHODOPI CENTRAL OF SULAWESI)

*Ir.Rahmat Muallim

*) Mine Plan Engineer, Vale Indonesia Mining Company tbk.

*) Intitution of Engineers Indonesia (IEI)

*) Makassar, Indonesia

*) [email protected]

ABSTRACT: Middle term planning of mine material handling Block 1a5a1517 will use equipment type of Komatsu which consists of loading truck PC 200 and hauling truck HD 255. The block has total material handlings (TMH) 9.579.750 Wmt which was divided in to three of block compartments in mining plan. The plan was to be achieved within 5 years and budget cost $1.052.571,15. The several steps have been conducted to fulfill the plan was including push back pit shell compartment method to determine total material handling perlevel, historical data by evaluating of distance and road width from test mining Myara Block to calculate maximum distance and road width plan based on equipment on site, equipment productivity data in Block 1a5a1517 which was calculated from equipment productivity (Wmt/hour – Wmt/day), equipment run (unit), equipment hour (hour), equipment cost (US$/jam), cycle time of equipment (hour), and equipment on site in every face pit shell compartment toward dumping point plan by using distance and velocity equipment data of Mine Modular System (MMS), physical availability (PA) data, and Use of Availabillity (UoA) data. All equipment productivity plan will be analyzed by using vehicle routing problem (VRP) method and software vulcan 7.5.Result of the anlysis indicated that would increase 21.85 meters for curve condition and 19.24 meters for straight condition. Number of equipments on site which would be implemented in 3 planned scenarios were scenario 01 has three units of PC 200 and five units of HD 255, scenario 02 has three units of PC 200 and four units of HD 255, and scenario 03 has three units of PC 200 and four units of HD 255. Distance of face to dumping point consists of three scenarios which were face pit shell compartment 01 – dumping point consists of face – disposal is 4.2 Km, and face – ROMpile is 3.7 Km, face – LGOpile is 6.2 Km; face pit shell compartment 02 – dumping point consists of face – disposal is 5.25 Km, face – ROMpile is 4.92 Km, and face – LGOpile is 7.2 Km; and face pit shell compartment 03 – dumpint point namely face – disposal is 1.9 Km, face – ROMpile is 1.9 Km, and face – LGOpile is 3.7 Km. Total material handling, time, and cost in every scenario were scenario 01 produced TMH of 464.002 Wmt, time was 4.99 years, and cost was US$ 905.561; scenario 02 produced TMH of 461.160 Wmt, time was 4.98, and cost was US$ 905.908; scenario 03 produced TMH was 483.554 Wmt, time was 4.97 and cost was US$ 907.205. Therefore, based on the results scenario 03 will be recommended for middle term planning in Block 1a5a1517.

Keywords : Pit shell compartment, Dumping point, Equipment productivity, Vulcan 7.5, and Vehicle routing problem (VRP).

1. PREFACE

Planning is qualification procedure to determine

target, activity, and tecnically sequence to

achieve the aims of mine activity. As the

Generally, planning will be defined in three of

phase namey long term planning by time phase

more than 5 years and continuously, middle

term planning by range 1 – 5 years in plan, and

short term planning by range weekly – monthly

in plan (Fuykschot, 2009)

Based on plan estimation time and cost in

Bahodopi are thus Block 1a5a1517 Bahodopi

Central of Sulawesi has target plan namely time

5 years and cost US$ 1.052.571,15 which block

2

divided in three of block compartment by

reserved 9.579.750 Wmt. Total material

handling (TMH) in this block has devided in

three of layer namely over burden (OB) will be

dumped in Disposal plan, ore in ROMpile and

low grade ore (LGO) in LGOpile by using type of

Komatsu Equipment namely loading truck PC

200 and hauling truck HD 255 (Waheed, 2005).

In Bahodopi Block, Myara block as Mine test

place which will be researched based to become

historical data by mining condition namely road

width 16 meters, type of equipment is Hino

truckby capacity 20 ton, and distance of material

handling namely face – Disposal is 12.41 Km,

face – 12.95 Km, and face – LGOpile 14.028 Km

which those cases were not fulfill mine distance

rule from PT Vale Indonesia that every distance

plan must under 10 Km for material handling.

Based on Total Material Handling (TMH), type

of equipment and distance material toward

dumping point plan so will be arranged plan

which united among three of component from

mine material handling by focus in middle term

planning constrains namely time 5 years and

cost US$ 1.052.571,15.

Therefore, to develop this plan thus several

resolutions plan will be implemented such as

block model evaluation design, the effect of type

of equipment in design and productivity, and

also control of material handling to dumping

point so that the plan will find the scenario who

will elaborate among those case in one system of

middle term planning scenario of mine material

handling.

2. RESEARCH METHODS

Research methods of Middle term planning of

mine material handling has showed number of

analysis to achieve of target plan from Block

1a5a1517 by using dispatching system method

that mentioned Vehicle routing problem (VRP)

in PT Vale Indonesia has called MMS (mine

modular system) which this system was

elaborating among total material handling pit

shell compartment which consist of three of pit

shell compartment, Productivity of loading truck

PC 200 and hauling truck HD 255 from type of

Komatsu equipment which will be calculated

prod/hour, prod/day, equipment run, equipment

hour, equipment cost and equipment on site and

also will controll distance and velocity of mine

material handling toward to dumping point. All

interaction among model, productivity and cycle

time will be described by sofware Vulcan 7.5 so

that born several scenarios which will be

fulfilled company recomendation target in

middle term planning.

3. ANALYSIS

3.1. Block 1a5a1517 Project Plan Area

Existing plan PT Vale Indonesia has three of

mining operation area namely Soroako area,

Petea area, and Bahodopi area which Block

1a5a1517 project plan area located in Bahodopi

plan with expose area 89 Ha from total area

32.123 Ha and distance from Soroako area

toward Block 1a5a1517 65 Km. This project so

far to determine efective plan to estabilsh mine

plan in this area. The area project plan will be

showed in figure 3.1 and 3.2 namely:

Figure 3.1 General distanced of existing plan PT.Vale

Indonesia (MGX, 2011)

Figure 3.2 Specific distanced Set up Petea to Block 1a5a1517

Based on figure 3.1 and 3.2 above so this

research will be calculated effective estimation

middle term planning of mine material handling

to open this area during 2013 – 2017 by target

plan are time 5 years and cost US$

1.052.571,15.

3

3.2.Push Back Pit Shell Compartment Block 1a5a1517 Plan.

Pit shell is a simplify pit design which consist of

both of boundary namley manual pit is the part

of pit design which the located of design at

outside of solid topography and optimization pit

(pit shell) is pit design that underlay with solid

topography so will indicate boundary pit shell of

pit design (Whittle, 2010).

That case will run with number of data namely

topography data and geometrical design data

that suitable with type of equipment who will

exist in mine activity in this block. Block

1a5a1517 will show input – process – output in

to design of pit shell compartment Block

1a5a1517 which will be presented on figure 3.3

and 3.4:

Figure 3.3 Topography Block 1a5a1517

Figure 3.4 Boundary block 1a5a1517 by CoG 1.7 Ni%

Based on figure 3.3 and 3.4 topography and

block model will be elaborated to make pit shell

compartment block 1a5a1517 namely (Degleden,

2001):

Figure 3.5 Pit shell compartment Block 1a5a1517.

Figure 3.3 has explained pit shell compartment

block 1a5a1517 that consist of three block pit

shell by total material handling namely:

Tabel 3.1 summary total material handling block 1a5a1517

Based on table 3.1 above we will look every pit

shell has produced layer material handling

namely Overburden (OB), Ore, and Low Grade

Ore (LGO). Those of materials will determine in

every push back pit shell compartment by level

bench 5 meters, angle slope 45o, and berm 3

meters with using PC 200 (SOP pit design,

2011). The condition of mine escavation will

show in figure 3.6:

Figure 3.6 Loading truck PC 200 in mine face Myara Block

Mining excavation in push back pit shell

compartment Block 1a5a1517 will present

material based on level bench to achieve

ultimate pit limit which each of TMH in level

bench include OB, Ore and LGO. Total material

handling will explain in bellow:

Table 3.2 TMH pit shell compartment 01 level 845 - 800

Material Comp_01 Comp_02 Comp_03

ob_vol 571783 105470 5091389

waste_vol 0.00 0.00 0.00

ore_vol 358879 59851 2642288

lgo1_vol 100556 16455 180678

lgo2_vol 72023 18629 361751

Total Material Movement (TMM)1103241 200405 8276106

SR (OB/(Ore+LGO)) 1.08 1.11 1.60

Summary Total Material Handling Blok 1a5a1517

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Table 3.3 TMH pit shell compartment 02 level 820 – 775

Table 3.4 TMH pit shell compartment 03 level

Based on TMH in pit shell compartment block

1a5a1517 so materials have completed to

remove in another dumping point which will be

designed suitable with material handling plan

from each of pit shell compartment in this area.

3.3.Infrastructure Plan of Mine Material

Handling Block 1a5a1517

Infrastructure plan in mine material handling is

the main idea to describe all condition which

plan will run as measure as the path plan.

According to the priority plan in this research so

infrastructure which will be established were

road width and dumping point plan design.

Then, after the infrastructure plan has succeed

so the correlation map of mine material

handling will be presented to estimate distance

and velocity for getting cycle time of mine

material handling. The number of infrastructure

plan to establish middle term planning of mine

material handling namely:

1. Road Width of Block 1a5a1517

Road width plan in mine material handling is

the important thing to design scenario of

equipment model and material for measuring

how the best mine plan scenario will

implement on one system of mine activity in

open pit mine area.

Block 1a5a1517 in Bahodopi Central of

Sulawesi is the target plan to make one of

effective scenario in middle term planning in

PT Vale Indonesia. The difference condition

among existing plan Bahodopi area in Myra

block than block 1a5a1517 namely equipment

problem set up in both of area. Myra block

used equipment type of Hino than Block

1a5a1517 equipment type of Komatsu so that

in implementing the mine plan design will

evaluate road width based on the specified of

equipment plan. The comparison of road

width dimension of hauling truck Hino and

HD 255 which pass in Bahodopi on mine road

PT Vale Indonesia will indicate in figure 3.5

and 3.6 namely:

Figure 3.7 Existing road width in Bahodopi (FEL, 2012)

Figure 3.8 Dimension of HD 255 (Komatsu, 2010)

Based on both of figure 3.6 and 3.7 thus will

be evaluated road width of mine material

handling Block 1a5a1517 by determining

road width based on the dimension of HD 255

as a truck plan in research area. The

evaluated divided in two side namely

evaluate road width in the curve condition

and straight condition by calculating of the

several value of road width coefficient to

completely the road design such as:

1) Calculating of road width in curve

condition

Number of input road width in curve

condition will be showed in figure 3.9 and

table 3.5:

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Figure 3.9 Road in curve condition (MHS 04, 2010)

Table 3.5 coefficient of Road width in curve condition

Based on table 3.5 the calculation of road

width in curve condition namely:

+ Fa + Fb + z) + C

+ 0.4 + 3.2 + 3.7) + 1.85

= 21.85 meter.

2) Calculating of road width in straight

condition

Number of input to calculate road width in

straight condition will show in figure 3.10

and table 3.6:

Figure 3.10 Road in straight condition (MHS 04, 2010)

Table 3.6 coefficient of Road width in straight condition

Based on table 3.6 the calculation of road

width in straight condition namely:

Wt + (n + 1) (1/2 Wt)

3.7 + (2 + 1) (1.85)

2. Dumping point plan Block 1a5a1517 Layer of push back pit shell compartment

Block 1a5a1517 consist of three kind of

materials namely Over Burden (OB), Ore and

Low Grade Ore (LGO) which OB will be

transported in Disposal plan, Ore will be

transported in ROMpile plan and LGO will be

transported in LGOpile plan. Dumping point

plan will be designed by following of material

volume from each pit shell compartment.

Those case will design by data bellow:

1) Disposal plan

Table 3.7 Geometry Disposal (MHS 10, 2010)

Based on table above so disposal plan will

design by Vulcan 7.5 will show in figure

3.11:

Figure 3.11 Disposal Plan MTP

Target OB 302.876 Wmt in total material

handling at pit shell compartment Block

1a5a1517 which disposal plan has fulfilled

the target of OB namely:

Table 3.7 Summary of Disposal Plan

2) ROMpile plan

Table 3.8 Geometry ROMpile (MHS, 2010)

Based on table above so disposal plan will

design by Vulcan 7.5 will show in figure

3.12:

Coeffiecient Value (m)

U (center to center tires) 2.7

Fa (front overhang) 0.4

Fb (back overhang) 3.2

Wt ( widht HD) 3.7

1/2Wt 1.85

Coeffiecient Value (m)

Wt (road width of truck) 3.7

n (number of gates) 2

1/2Wt 1.85

angle 45/26 derajat

project_level R-5

Height 5 meter

Geometri Design Disposal

Triangulation Volume(Wmt)

s_bdisp_st_01 105000



total 470493

Disposal plan Middle term planning

angle 45 derajat

berm 3 meter

project_level R5(cut)/R-5(fill)

Height 5 meter

Geometri Design of ROMpile

6

Figure 3.12 ROMpile plan MTP

Target ROM (Run of Mining)/Ore in total

material handling in middle term

planning Block 1a5a1517 is 176.768 Wmt

which ROMpile plan has fulfilled the

target of Ore capacity by result:

Table 3.9 Summary of ROMpile plan

3) LGOpile plan

Table 3.10 Geometry LGOpile

Based on table above thus LGOpile plan

design will show in figure 3.13:

Figure 3.13 LGOpile plan MTP

Target LGO in middle term planning is

33.543 Wmt Which LGOpile plan has

fullfiled designed and target by capacity

result namely:

Table 3.11 Summary of LGOpile plan

Based on Dumping point plan Middle term

planning of mine material handling block

1a5a1517 thus mine material handling will

conduct for finishing of target plan from block

1a5a1517.

3. Overview situation distance and velocity

target plan in middle term planning of mine

material handling block 1a5a1517 1) Existing distance plan of Myra Block in

Bahodopi area

Figure 3.14 Overview distance of Myra Block

Based on material transport in Bahodopi

material to dumping distance not more

than 10 km but in the Myara case as

existing plan didn’t represent Bahodopi

plan project area so needed evaluation at

athe dumping point distances.

2) Middle term planning (MTP) of Block

1a5a1517 in Bahodopi area

Figure 3.15 Overview distance of dumping point MTP

Based on figure 3.15 so as detail distance in

each pit shell compartment Block 1a5a1517

toward dumping point plan thus will show

in figure bellow namely:


scut_rompile_01 157179.414

sfill_rompile_01 136589.473

Rompile Plan MTP

angle 45 derajat

berm 3 meter

project_level R5(cut)/R-5(fill)

Height 5 meter

Geometri Design of LGOpile


scut_LGOpile 67130

sfill_LGOpile 66100

Total 133230

LGOpile of MTP

7

Figure 3.16 Distance pit shell comp. 01 – Dumping

point

Based on figure 3.16, the distance of pit

shell compartment 01 to dumping point

namely Face – Disposal is 4.2 Km, Face –

ROMpile is 3.7 Km and Face – LGOpile is

6.2 Km. Then, Distance Pit shell

compartment 02 will be showed in figure

3.17:

Figure 3.17 Distance pit shell comp.02 – Dumping

point

Based on figure 3.16 above the distance of

pit shell compartment 01 to dumping point



7.2 Km. The last distance will be showed in

figure 3.18:

Figure 3.18 Distance pit shell comp.03 – Dumping

point

Based on figure 3.16 above the distance of

pit shell compartment 01 to dumping point



7.2 Km.

Based on all of figure above thus all of distance

has fulfilled of target distances to continue of

middle term planning and available with

material handling rule in PT Vale Indonesia

under value 10 Km to handle the material.

3.4. EquipmentProductivity of Loading Truck PC 200 and Hauling Truck HD 255 Equipment productivity explained number of

equipment calculation to achieve the material

handling to dumping point. There are two

equipment have used in mine material handling

Block 1a5a1517 namely loading truck PC 200

and hauling truck HD 255 by Komatsu type. The

several data will be founded in equipment

calculation namely:

1. Productivity data of loading truck PC 200 and

hauling truck HD 255

Table 3.12 Productivity data in Bahodopi area

2. Shift code 10H16 of Bahodopi equipment data

which have operational working hour (OWH)

is 7.72 hour and effective working hour

(EWH) is 6.95 hour.

3. Material duration in each level bench

material by assump one year = 365 days =

8765 hours.

4. Estimation of loading cost PC 200 is US$

26.94 and hauling cost HD 255 is US$ 19.29

in Bahodopi area.

5. Distance and velocity data mine material

handling from pit shell compartment Block

1a5a1517 to dumping point plan by using

MMS (Mine Modular System) so that will

create cycle time of equipment in material

handling scenarios of middle term planning.

Cycle time material will explain based on

equation bellow (Komatsu Handbook, 2010):

…………………….. (2.1)

Remarks:

CT : Cycle time (hour)

Equipment Unit PC 200 TRUCK HD 255 PC 200 TRUCK HD 255

ROM density t/m3 1.74 1.74 1.62 1.62

Swell Factor 20.00% 20.00% 20.00% 20.00%

ROM loose density t/m3 1.45 1.45 1.35 1.35

Spotting Time (haul truck) Minutes 0.40 0.40

Waiting truck (load equipment)-LEFT, Deadload capacity-RIGHT 1.00 0.98 1.00 0.98

Dumping Time Minutes 0.50 0.50

Equipment specification m3 1.00 13.02 1.00 13.02

ROM fill factor 90.00% 97% 90.00% 97%

ROM Cycle Per Pass Minutes 0.60 0.60

ROM number of pass 15.00 15.00 15.00 15.00

ROM loading time 9.00 9.00

ROM loaded on truck WMT 19.58 18.23

ROM loading equipment productivity 117.45 109.35

level material by bench 81.00 13.50 81.00 13.50

Striping OB ROM/LGOMINING

8

CP : Cycle per pass (minutes)

NP : Number of pass

D1 : Distance in forward (Km)

V1 : Velocity in forward (Km/hour)

t1 : Dumping time (minutes)

D2 : Distance in return (Km)

V1 : Velocity in return (Km/hour)

t2 : Spotting time (minutes)

Based on the cycle time equation above thus

will calculate cycle time at three of pit shell

compartment in Block 1a5a1517 namely:

Table 3.13 Cycle time pit shell comp. 01



Based on the several data above thus the

calculating of productivity PC 200 and HD

255 will be presented in equation bellow:

1. Prod/hour

1) PC 200

...............(2.2)

2) HD 255

…………....(2.3)

2. Prod/day

3. Equipment run

4. Equipment on site (EoS)

EoS = Round up (TMH pit shell x PA x UoA;0)…(2.6)

5. Equipment hour (EH)

EH = ER x OWH x Work duration per level ……. (2.7)

6. Equipment cost (EC)

…………. (2.8)

Based on productivity equation thus will

presented the calculation form of productivity

from PC 200 and HD 255 and TMH pit shell

bench level 5 meters in this research namely:

Table 3.16 Productivity PC 200 and HD 255

Figure 3.19 TMH pit shell per bench

3.5. Dispatching System Scenario of Middle Term Planning Block 1a5a1517

Dispatching system scenario is the interaction

model which elaborate reserved model material,

infrastructure of mine material handling,

equipment on site in this case PC 200 and HD

255 and also distance dumping point for

removing material to each dumping point. The

theoretical model will be showed in figure 3.20

(Bissiri et al, 2011):

Figure 3.20 block - loading truck - hauling truck – target

(Bissiri et all)

Based on figure 3.20 this research has used Ant

colony theory to describe activity cycle time of

material in block 1a5a1517. Therefore, the

calculation of dispatching system scenario will

be presented by Vehicle Routing Problem (VRP)

that emphasize two cases namely Vehicle

Capacity Routing Problem (VCRP) which totally

explain about productivity PC 200 and HD 255

and Vehicle Routing by Time Windows (VRTW)

which explain about cycle time of equipment in

mining area in pit shell compartment Block

t1 t2

forward return WT + DT ST

Face - disposal 4.2 22.1 22.1 0.99 0.01 2.90

Face - Rompile 3.7 20.4 20.4 0.99 0.01 2.81

Face - LGOpile 6.2 27.8 27.8 0.99 0.01 3.23

total CT 8.93

Lokasi distance (km)average speed (km/h)

CT HD-255 (hour)

t1 t2


Face - disposal 5.25 25.05 25.05 0.99 0.01 3.09

Face - Rompile 4.92 22.29 22.29 0.99 0.01 3.20

Face - LGOpile 7.2 25.29 25.29 0.99 0.01 3.84

total CT 10.14

CT HD-255 (hour)Lokasi distance (km)average speed (km/h)

t1 t2


Face - disposal 1.90 11.40 11.40 0.99 0.01 2.66

Face - Rompile 1.40 8.40 8.40 0.99 0.01 2.66

Face - LGOpile 3.70 20.43 20.43 0.99 0.01 2.81

total CT 8.13

Lokasi distance (km)average speed (km/h)

CT HD-255 (hour)

aktivitas loading PC 200 L-820

Prod/jam(Wmt) 81.00

Prod/day(Wmt) 562.79

Eq. Run 0.00

Eq. Hours loading(hour/Wmt) 14.53

Eq.cost loading (hour/$) 391.41

aktivitas hauling HD 255 L-820

Prod/jam(Wmt) 13.50

Prod/day(Wmt) 93.80

Eq. Run 0.02

Eq. Hours hauling(hour/Wmt) 97.30

Eq.cost hauling (hour/$) 1876.46

9

1a5a1517 (Subtill et al., 2011). VRP in scenario

of middle term planning PT Vale Indonesia will

use MMS (Mine Modular System) in figure 3.20:

Figure 3.20 MMS dispatching system (Haymes, 2004)

Based on the figure 3.20 about VRP thus will

determined cost and time which searched from

interaction of model, equipment productivity

and cycle time of mine material handling in

Block 1a5a1517 by equation form namely (SOP

equipment calculation in PT Vale Indonesia,

2012):

1. Time in level mine material handling Block

1a5a1517

…... (2.9)

2. Cost in level mine material handling Block

1a5a1517

(2.10)

Based on those theoretical about dispatching

system thus scenario middle term planning of

mine material handling Block 1a5a1517 will

plan in the three of scenario which will varied

based on pit shell compartment which time 5

years and cost US$ 1.052.571,15 so that this

scenario will present:

1. Scenario 01 Block 1a5a1517

Scenario 01 consist of pit shell compartment

01 level 845-800, pit shell compartment 02

level 820 – 810, and pit shell compartment 03

level 995 – 985 which Pit shell compartment

01 is the firstly step to start this scenario.

There are several steps to analysis those of

scenario namely:

1) Total material handling (TMH) scenario

01

There are three of mine face based on pit

shell compartment in scenario 01 namely:

Table 3.17 TMH pit shell comp. 01 L-845 – L-800

Table 3.18 TMH pit shell comp. 02 L-820-L-810

Table 3.19 TMH pit shell comp.03 L-995 – L-985

Based on tables above thus TMH scenario

01 will be showed in table 3.20:

Table 3.20 Summary TMH scenario 01

2) Equipment productivity loading truck PC

200 and hauling truck HD 255

Equipment productivity PC 200 and HD

255 in push back pit shell compartment

scenario 01 will be showed in tables

bellow:

Table 3.21 Equipment productivity of L-845-L-800


Region TMH

spit_1a5a1517_comp_01_845.00t 30

spit_1a5a1517_comp_01_840.00t 4072

spit_1a5a1517_comp_01_835.00t 45436

spit_1a5a1517_comp_01_830.00t 64860

spit_1a5a1517_comp_01_825.00t 67648

spit_1a5a1517_comp_01_820.00t 59759

spit_1a5a1517_comp_01_815.00t 41514

spit_1a5a1517_comp_01_810.00t 36797

spit_1a5a1517_comp_01_805.00t 40694

spit_1a5a1517_comp_01_800.00t 46450

Total 407260

TMH Pit shell compartment 01 level 845 - 800

Region TMH

spit_1a5a1517_comp_02_820.00t 1059

spit_1a5a1517_comp_02_815.00t 6984

spit_1a5a1517_comp_02_810.00t 24869

Total 32912


Region TMH

spit_1a5a1517_comp_03_995.00t 272

spit_1a5a1517_comp_03_990.00t 1826

spit_1a5a1517_comp_03_985.00t 21732

Total 23830


Material TMH(Wmt) TMH (day)

Pit shell compartment 01 L-845-L-800 (face 01) 407260 1118.85



Total 464002 1274.73

Summary TMH In Each Mine Face

aktivitas loading PC 200 L-845 L-800 Tot.loading

Prod/jam(Wmt) 81.00 81.00

Prod/day(Wmt) 562.79 562.79

Eq. Run 0.00 0.03

Eq. Hours loading(hour/Wmt) 0.41 637.17 4843.49

Eq.cost loading (hour/$) 11.09 17168.08 184391.69

aktivitas hauling HD 255 L-845 L-800 Tot.hauling


Prod/day(Wmt) 93.80 93.80

Eq. Run 0.00 0.17

Eq. Hours hauling(hour/Wmt) 11.40 3831.98 33608.64

Eq.cost hauling (hour/$) 219.85 73904.32 648183.65

38452.13

832575.34

Total waktu loading dan hauling (hour)

Total cost loading dan hauling ($)

10


Based on equipment productivity in every

push back pit shell compartment of

scenario 01 thus will be calculated the

number of equipment on site PC 200 and

HD 255 in this scenario which will be

showed in table 3.24:

Table 3.24 Number of equipment on site scenario 01

Based on table 3.2 has been founded the

number of equipment PC 200 and HD 255

namely 3 units for PC 200 and 5 units for

HD 255 in scenario 01.

3) Scenario design of middle term planning

Scenario design in scenario 01 will be

designed by Vulcan 7.5 by resulting of

MTP map scenario 01 will be showed in

figure 3.21 namely:

Figure 3.21 MTP map of scenario 01

4) Middle term planning result of scenario 01

Middle term planning (MTP) of mine

material handling scenario 01 is

integrating of TMH, equipment

productivity and distance among material

to dumping point so that will be showed

the result of MTP in scenario 01 namely:

Table 3.25 Summary scenario 01 MTP



02 level 820 – 775, pit shell compartment 01

845 – 825 and pit shell compartment 03 level

995 – 980 which pit shell compartment 02 is

the firstly step to start this scenario. Similar

with scenario 01 thus scenario 02 also has

several steps to analysis its scenario namely:


01



Table 3.26 TMH pit shell comp.02 L-820-L-775

Table 3.27 TMH pit shell comp. 01 L-845-L-825

aktivitas loading PC 200 L-820 L-810 Total loading


Prod/day(Wmt) 562.79 562.79

Eq. Run 0.00 0.08



aktivitas hauling HD 255 L-820 L-810 Total hauling



Eq. Run 0.02 0.48



3190.68

64993.43

Total waktu loading dan hauling

Total cost loading dan hauling



Prod/day(Wmt) 562.79 562.79

Eq. Run 0.00 0.00


Eq.cost loading (hour/$) 100.53 8032.22 8,807.65

aktivitas hauling HD 255 L-995 L-985 Total haulingProd/jam(ton) 13.50 13.50

Prod/day(ton) 93.80 93.80

Eq. Run 0.00 0.01

Eq. Hours hauling(hour) 30.52 1796.77 1,857.80

Eq.cost hauling (hour/$) 588.54 34652.93 35,830.01

Total waktu loading dan hauling 2,184.69

Total cost loading dan hauling 10,992.34

Prod/jam(Wmt) 81.00 Prod/jam(Wmt) 81.00 Prod/jam(Wmt) 81.00

Prod/day(Wmt) 562.79 Prod/day(Wmt) 562.79 Prod/day(Wmt) 562.79

Eq. Run 0.57 Eq. Run 0.05 Eq. Run 0.03

Eq on site (alat yang ada) 1 Eq on site (alat yang ada) 1 Eq on site (alat yang ada)1




Eq on site (alat yang ada) 3 Eq on site (alat yang ada) 1 Eq on site (alat yang ada)1

aktivitas hauling HD 255 aktivitas hauling HD 255 aktivitas hauling HD 255

aktivitas loading PC 200 aktivitas loading PC 200 aktivitas loading PC 200

Pit shell compartment 01 Pit shell compartment 02 Pit shell compartment 03

Target MTP Face 01 face 02 face 03 Tot. scenario total scenario (year)time (hour) 38452.13 3190.68 2184.69 43827.50 5.00

cost (US$) 832575.34 64993.43 10992.34 908561.11

Region TMH

spit_1a5a1517_comp_02_820.00t 1059

spit_1a5a1517_comp_02_815.00t 6984

spit_1a5a1517_comp_02_810.00t 24869

spit_1a5a1517_comp_02_805.00t 32695

spit_1a5a1517_comp_02_800.00t 33592

spit_1a5a1517_comp_02_795.00t 33897

spit_1a5a1517_comp_02_790.00t 28707

spit_1a5a1517_comp_02_785.00t 28681

spit_1a5a1517_comp_02_780.00t 9858

spit_1a5a1517_comp_02_775.00t 63

Total Material in level 200405

TMH pit shell compartment 02 level 820 - 775

11


Based on tables 3.28, TMH scenario 01

will be showed in table 3.29:

Table 3.29 Table TMH of scenario 02






bellow:


Table 3.31 Equipment productivity of L-845 – L-825

















figure 3.22 namely:








the result of MTP in scenario 02 namely:

Table 3.34 Summary scenario 02 of MTP

Region TMH

spit_1a5a1517_comp_01_845.00t 30

spit_1a5a1517_comp_01_840.00t 4072

spit_1a5a1517_comp_01_835.00t 45436

spit_1a5a1517_comp_01_830.00t 64860

spit_1a5a1517_comp_01_825.00t 67648


TMM Pit shell compartment 01 level 845 - 825

Region TMH

spit_1a5a1517_comp_03_995.00t 272

spit_1a5a1517_comp_03_990.00t 1826

spit_1a5a1517_comp_03_985.00t 21732

spit_1a5a1517_comp_03_980.00t 54879




Pit shell compartment 02 L-820--L-775 (face 01) 200405.00 549.05

Pit shell compartment 01 L-845-L-820 (face 02) 182046.00 498.76

Pit shell compartment 03 L-995-L-980 (face 03) 78709.00 215.64

Total 461160 1263.45

TMH In Each Mine Face



Prod/day(Wmt) 562.79 562.79

Eq. Run 0.00 0.02






Eq. Run 0.02 0.14



Total waktu loading dan hauling (hour) 18,544.63

Total cost loading dan hauling ($) 394,136.56



Prod/day(Wmt) 562.79 562.79

Eq. Run 0.00 0.04

Eq. Hours loading(hour/Wmt) 0.41 927.96 2,497.20

Eq.cost loading (hour/$) 11.09 25002.93 67,284.82




Eq. Run 0.00 0.25

Eq. Hours hauling(hour/Wmt) 11.40 5576.67 15,027.86

Eq.cost hauling (hour/$) 219.85 107,552.82 289,830.61

Total waktu loading dan hauling (hour) 17,525.06

Total cost loading dan hauling ($) 357,115.43



Prod/day(Wmt) 562.79 562.79

Eq. Run 0.00 0.00






Eq. Run 0.00 0.03



7,590.31

154,656.45 Total cost loading dan hauling ($)





Eq on site (alat yang ada) 1 Eq on site (alat yang ada) 1 Eq on site (alat yang ada) 1








12



03 level 995 – 970, pit shell compartment 01

level 845 – 830 and pit shell compartment 02

level 820 – 800 which pit shell compartment

03 is the firstly step to start this scenario.

Similar with scenario 01 and 02 thus scenario

03 also has several steps to analysis its

scenario namely:


01






Based on tables above thus TMH scenario

01 will be showed in table 3.38:

Table 3.38 Summary TMH of Scenario 03






bellow:











Target MTP Face 01 face 02 face 03 Tot. scenario total scenario (year)time (hour) 18544.63 17525.06 7590.31 43660.00

cost ($) 394136.56 357115.43 154656.45 905908.444.98

Region TMH

spit_1a5a1517_comp_03_995.00t 272

spit_1a5a1517_comp_03_990.00t 1826

spit_1a5a1517_comp_03_985.00t 21732

spit_1a5a1517_comp_03_980.00t 54879

spit_1a5a1517_comp_03_975.00t 88588

spit_1a5a1517_comp_03_970.00t 102650



Region TMH

spit_1a5a1517_comp_01_845.00t 30

spit_1a5a1517_comp_01_840.00t 4072

spit_1a5a1517_comp_01_835.00t 45436

spit_1a5a1517_comp_01_830.00t 64860



Region TMH

spit_1a5a1517_comp_02_820.00t 1059

spit_1a5a1517_comp_02_815.00t 6984

spit_1a5a1517_comp_02_810.00t 24869

spit_1a5a1517_comp_02_805.00t 32695

spit_1a5a1517_comp_02_800.00t 33592


TMH pit shell compartment 02 level 820 - 800


Pit shell comprtment 03 Level 995 -970 (face 01) 269947.00 739.58

Pit shell compartment 01 Level 845 - 830 (face 02) 114398.00 313.42

Pit shell compartment 02 Level 820 - 800 (face 03) 99199.00 271.78

Total 483544 1324.78

Summary TMH In Each Mine Face



Prod/day(Wmt) 562.788 562.788

Eq. Run 0.00 0.008022126

Eq. Hours loading(hour/Wmt) 3.73 1,408.09 3,702.98

Eq.cost loading (hour/$) 100.53 37,939.79 97,773.33



Prod/day(Wmt) 93.798 93.798

Eq. Run 0.0001275 0.048132754

Eq. Hours hauling(hour/Wmt) 30.52 8,496.56 19,306.51

Eq.cost hauling (hour/$) 588.54 163,866.52 400208.21

23,009.48

497,981.54





Prod/day(Wmt) 562.788 562.788

Eq. Run 0.00 0.040408834





Prod/day(Wmt) 93.798 93.798

Eq. Run 0.000112 0.242453004


Eq.cost hauling (hour/$) 219.85 103,127.31 172265.79

11,020.44

214,119.93





Prod/day(Wmt) 562.788 562.788

Eq. Run 0.0034178 0.108413624





Prod/day(Wmt) 93.798 93.798

Eq. Run 0.0205067 0.650481747


Eq.cost hauling (hour/$) 1,876.46 53,517.50 158,440.20

9,575.96

195,104.48














13









figure 3.23 namely:








the result of MTP in scenario 03 namely: Table 3.43 Summary scenario 03 0f MTP

Based on all of scenario Middle term planning of

mine material handling has fulfilled target cost

and time Bahodopi area namely cost US$

1.052.571,15 and Time 5 years.

4. Strength and weakness of all scenario as

recommendation plan on Block 1a5a1517 in

opening mine area at Bahodopi Central of

Sulawesi at 2013 – 2017.

The purpose of this research in to explain

strength and weakness all of scenario from

Block 1a5a1517 is informing to the company

to choose the best compartment from

economy and technology decision so that

opening area in Bahodopi at 2013 – 2017 will

be achieved and increased of company target

in the future. The several strength and

weakness from number of scenarios namely:

1) Scenario 01

(1) Strength

The strength of scenario 01 based on

MTP of mine material handling in this

block namely:

a) The starting plan of Mine face has

located in the center of block so that

easy to access pit shell 02 and 03

b) Equipment access easier caused

equipment on site more flexible to

continue its schedule.

c) Time and cost has fulfilled middle

term planning (MTP) target

(2) Weakness

The weakness of scenario 01 based on


block namely:

a) Imperfectly of TMH will be removed

in scenario 01 there are level not all

ready clean up on this scenario

b) The number of equipment so many

than scenario 02 and scenario 03

c) Needed of new dumping point to

cover all of TMH in Block 1a5a1517

2) Scenario 02

(1) Strength



block namely:

a) Scenario 02 has mine out and mine

face will continue to pit shell

compartment 02 and 03

b) Mine out from pit shell compartment

02 will able to become a in pit

disposal as mine sustainable plan in

this block

c) Its road plane in this scenario has

sustained to access all of TMH in

every pit shell without road cutting.

(2) Weakness

The weakness of scenario 01 based on

on MTP of mine material handling in

this block namely:

a) The Distance of Pit shell

compartment 02 so far to start of

mine activity than pit shell

compartment 01 and 03

b) TMH is so small to start of mine

activity

3) Scenario 03

(1) Strength



block namely:

a) The distance of pit shell

compartment 03 of more closer than

pit shell compartment 01 and 02 to

start of mine activity

b) Equipment on site in this scenario

not more than another activities

c) TMH from pit shell compartment 03

is to many than pit shell

Target MTP Face 01 face 02 face 03 Tot. scenario total scenario (year)

time (hour) 23009.48 11020.44 9575.96 43605.88

cost ($) 497,981.54 214119.93 195104.48 907205.954.98

14

compartment 01 and 02 in to start of

mine activity

(2) Weakness

The weakness of of scenario 03 based on


block namely:

a) The biggest exposed area in to start

this scenario will cut of the access

road to finish this plan

b) There is a separate material from pit

shell compartment 03 so needed new

access road to take this material.

4. CONCLUSIONS

Based on the interaction among Total

material handling (TMH) pit shell

compartment Block 1a5a1517,

infrastructure design and distance face to

dumping point by used dispatching system

of vibrating routing problem thus has been

achieved the company target of PT Vale

Indonesia namely time 5 years and cost US$

1.052.571,15. The several conclusions from

this block namely:

1. Road width from this block consist of in

two conditions namely in curve condition

is 21.85 meters and in straight condition

is 19.24 meters.

2. Number of distance from middle term

planning of mine material handling

Block 1a5a1517 namely pit shell

compartment 01 consist of distances face

– Disposal is 4.2 Km, face – ROMpile is

3.7 Km and Face – LGOpile is 6.2 Km;

pit shell compartment 02 consist of

distances face – Disposal is 5.25 Km,

face – ROMpile is 4.92 Km and face –

LGOpile is 7.2 Km; and pit shell

compartment 03 consist of distances face

– Disposal is 1.9 Km, face – ROMpile is

1.4 Km and face – LGOpile is 3.7 Km.

3. The number of loading truck PC 200 and

hauling truck HD 255 to fulfilled middle

term planning scenario of Block

1a5a1517 namely scenario 01 consist of

3 units of PC 200 and 5 units of HD 255,

scenario 02 consist of 3 units of PC 200

and 4 units of HD 255 and scenario 03

consist of 3 units of PC 200 and 4 units

of HD 255.

4. Total material handling (TMH), time

and cost in each scenarios namely

scenario 01 have TMH is 464.002 Wmt,

Time 4.99 years, and cost is US$ 908.561,11; scenario 02 have TMH is

461.160 Wmt, time is 4.98 years and cost

is US$ 905.908,44; scenario 03 have

TMH is 483.554 Wmt, time is 4.97 years

and cost is US$ 907.205,95 so that

scenario recommended for Block

1a5a1517 namely scenario 03.

ACKNOWLEDGEMENT

The author would like to express gratitude

towards Contract of Work (CoW) Project Mine

Development in Mine Plan Division PT Vale

Indonesia for the opportunity to conduct this

research

REFERENCES

.

(1) Bissiri., Scot., and Alan. 2011. Swarm-Based Truck-Shovel Dispatching System in Open Pit Mine Operations. Department of Mining and Mineral Process

Engineering University of British Columbia.

Vancauver, B., C: Canada..

(2) Dagleden. 2001. Open Pit Optimization Starategic For Improving Economic of Mining Project through Mine Planing. 17th International Mining Congress and

Exhibition:Turkey.

(3) Drew. 2012. Stochastic Dynamic Optimization of Cut-off Grade in Open Pit Mines. Queen’s University: Canada

(4) Fuykschot. 2009. Strategic Mine Planning ; Flexible Planning to Meet Changes in the Business Environment. SRK Consulting: MINEX Conference..

(5) Khustrulid, W and Kuchta, M. 2004. Open Pit Mine Planning & Design. London: Balkema Publishers

(6) Milan, B. 2009. Bulk Material Transportation System In Open Pit Mines With Improve Energy Eficiency.

University In Belgrade journal : Serbia.

(7) MGX, 2011. Mine geology training PT Vale Indonesia.

Soroako (Unpublished report)

(8) Mayor Hazard Standart (MHS) 4 dan 10 PT Vale Indonesia. 2000.Slope Stability.Soroako (Unpublished

report)

(9) PT. Vale Indonesia. 2012. Feasibility Study 3 – Cepat . Mine Plan Section. Soroako. (Unpublished report)

(10) Stermole, F. 2001. Economic and Evaluation Decision Methods. Investment Evaluations Cooperation 3070 :

South Newcombe Way, Colorado

(11) Subtill., Silva., and Alves. 2011. A Practical Approach To Truck Dispatch For Open Pit Mines. 35th APCOM

Symposium. Wollongsong: Rusia.

(12) Standar Operasional Prosedur (SOP) Pit Design dan CoG sensitivity PT Vale Indonesia. 2011. Soroako.(

Unpublished report).

(13) Waheed.2005. Mine Geology at PT INCO. PT Vale

Indonesia : Soroako.

(14) Whittle. 2010. Simultaneous Mining and Mineral Processing Enterprise Optimization For The Platinum Industry. The 4th International Platinum Conference :

Southern of Africa.

15

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