Mine Traffic Simulation

Kusmunda Mine
SECL

Mano Kanthanathan
Commercial Consultancy Services
mano@ccsstrategy.com
www.flexsim.com
December 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

Traffic & Mine Performance Metrics

Vehicles waiting at
Intersections
Load zones
Weigh bridges

Mine output for Coal and OB

Scenario Comparison
Safety distance and intersection rules enforced in all truck movements
Commercial Consultancy Services Bangalore, India

Mine Model Input Parameters

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
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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

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Kusmunda Mine Simulation Model

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Scenarios Examined for Kusmunda Mine

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
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Scenarios Examined for Kusmunda Mine contd.

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
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Scenarios Truck Numbers & Loader

ESM2

MAHAVIR
COAL

ROAD
SELL

BCM

AKT

SECL

TOTAL

SMAS OB

SMAS
COAL

272

45

25

60

10

14

55

10

15

38

NO CHANGE

SCENARIO 1

240

25

60

10

14

55

10

15

51

ONE MORE LOADER

SCENARIO 2

240

25

60

10

14

55

10

15

51

ONE MORE LOADER

ONE MORE LOADER

IN ALL CONTRACT
ROUTES

57

ONE MORE LOADER

IN ALL CONTRACT
AND SECL ROUTES

BASE
SCENARIO

SCENARIO 3

351

PERCENT
INCREASE

29%

SCENARIO 4A
and 4B

408

PERCENT
INCREASE

50%

68

68

38

38

ESM1

90

90

15

15

21

21

83

83

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15

15

23

23

LOADER

Base Scenario

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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 in

amount of time each vehicle waits at intersection!

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Traffic Congestion Load Zones Base Scenario

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Traffic Congestion Weigh Bridges Base Scenario

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Mine Output Coal Base Scenario

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Total Coal Output - yearly estimate is around 20.7 Million tons

Mine Output OB Base Scenario

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Total OB Output yearly estimate is around 23.9 Million tons

Scenario 1
50% more SECL vehicles for OB
One more loader
No SMAS OB

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Traffic Congestion Intersection Scenario 1

Congestion observed at:
QJ2 for OB vehicles is 16 vehicles

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Mine Output Coal Scenario 1

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Total Coal Output - yearly estimate is around 23 Million tons

Mine Output OB Scenario 1

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Total OB Output yearly estimate is around 27.9 Million tons

Scenario 2
50% more SECL vehicles for OB
One more loader
No SMAS OB
Two lane roads for OB removal

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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 using
a two lane road

Commercial Consultancy Services Bangalore, India

Mine Output OB Scenario 2

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

Total OB Output yearly estimate is around 27.3 Million tons slightly less than Scenario 1

Mine Output Coal Scenario 2

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

Total Coal Output - yearly estimate is around 23.2 Million tons almost same as Scenario 1

Scenario 3
50% more Contractual Vehicles for Coal & OB
No SECL vehicles
One more loader in each route for Contractual vehicles

Commercial Consultancy Services Bangalore, India

Traffic Congestion Intersection Scenario 3

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

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Mine Output Coal Scenario 3

ROADSELL may be
limited by traffic
congestion as compared
to ESM1

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Total Coal Output - yearly estimate is around 19.4 Million tons

Mine Output OB Scenario 3

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Total OB Output yearly estimate is around 6.5 Million tons

Scenario 4
50% more Contractual and SECL Vehicles for Coal & OB
Sub scenario 4A One more loader in each route
Sub scenario 4B No increase in loader

Commercial Consultancy Services Bangalore, India

Traffic Congestion Intersection Scenario 4A

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

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Mine Output Coal Scenario 4A

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Total Coal Output - yearly estimate is around 28.7 Million tons

Mine Output OB Scenario 4A

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Total OB Output yearly estimate is around 32.8 Million tons

Traffic Congestion Intersection Scenario 4B

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

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Mine Output Coal Scenario 4B

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Total Coal Output - yearly estimate is around 28 Million tons

Mine Output OB Scenario 4B

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Total OB Output yearly estimate is around 31.4 Million tons

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

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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

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Scenario Development in Mine Traffic

Input Tables for:
1.
2.
3.
4.

Truck numbers for each route

Load and Unload time of trucks
Differing speeds
Differing Truck capacities

Input data can be fed directly from

a Excel spreadsheet into the Kusmunda
Model 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
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Queries