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COMPUTER SIMULATION OF THE M I N I N G OPERATIONS I N

OPENCAST L I G N I T E MINES OPERATING BWES, CONVEYORS


AND STACKERS

G.N. PANAGIOTOU

DEPARTMENT OF M I N I N G ENGINEERING

N A T I O N A L TECHNICAL UNIVERSITY OF ATHENS

ABSTRACT

SIMPTOL, a computer s i m u l a t i o n program w r i t t e n i n FORTRAN


I V f o r u s e w i t h Cyber 1 7 1 / 8 System a t t h e N a t i o n a l T e c h -
n i c a l U n i v e r s i t y of Athens, d e s c r i b e s t h e mining opera-
t i o n s i n a n o p e n c a s t l i g n i t e mine o p e r a t i n g B u c k e t Wheel
E x c a v a t o r s , Conveyors a n d S t a c k e r s . The c e n t r a l o b j e c t i v e
o f t h e program i s t o a i d management i n t h e s e l e c t i o n o f
a BWE-Conveyor-Stacker System f o r a g i v e n l i g n i t e d e p o s i t
and e q u i p m e n t l a y o u t . Much i n f o r m a t i o n c a n be g a i n e d from
t h e program w i t h p r o p e r m a n i p u l a t i o n o f t h e i n p u t d a t a ,
which r e f e r t o m i n i n g p r o f i l e , s o i l c h a r a c t e r i s t i c s , e q u i p -
ment s p e c i f i c a t i o n s a n d a v a i l a b i l i t i e s a n d t i m e s t u d y d a t a .
The o t h e r o b j e c t i v e o f t h e program i s t o a i d p r o d u c t i o n
scheduling i n terms of f o r e c a s t i n g production r a t e s of
t h e s y s t e m . The program h a s been a p p l i e d t o K a r d i a l i g n i t e
mine t o e v a l u a t e i t s u s e f u l n e s s t o r e p r e s e n t t h e a c t u a l
s i t u a t i o n of t h e system being simulated.
USE OF COMPUTERS IN COAL INDUSTRY
m

INTRODUCTION 15000.
MW

W i t h a p r o d u c t i o n o f 1 2 0 . 5 toe*, i n 1 9 8 0 ,
l i g n i t e mining i n d u s t r y h a s a n o t a b l e c o n t r i -
b u t i o n t o t h e w o r l d p r c ~ d u c t i o no f m i n e r a l
f u e l s . The e n e r g y c r i s i s f o r c e d t h e e x p l o r a - - -11
- -2
- -7. 2
t i o n and e x p l o i t a t i o n o f low c a l o r i f i c v a l u e I I
c o a l s - l i g n i t e s - u n d e r t h i c k overburden masses, I I
10000- I I
i n order, nations with such resources, t o I I
become more i n d e p e n d e n t o f o i l i m p o r t s . I I
I I
G r e e c e , i n 1 9 8 0 , ~ r o d u c e d3 . 0 toe' w h i c h I I
I I
r e p r e s e n t t h e 2.5% o f t h e world p r o d u c t i o n I
o r t h e 9 . 4 % o f EEC p r o d u c t i o n . The i m p o r t -
ance o f l i g n i t e i n meeting Greece's energy
5 6 4 2 1 r
5573
------3

n e e d s i s o b v i o u s f r o m F i g u r e 1 . The s t a t e - 1I 4315
r------1
owned P u b l i c Power C o r p o r a t i o n ( P P C ) o p e r a - 1 I
t e s t h e m a j o r i t y of l i g n i t e d e p o s i t s ; t h r e e I I I

s m a l l d e p o s i t s a r e m i n e d by p r i v a t e compa- 1 2513 1

n i e s . L i g n i t e i s m a i n l y b u r n t i n t h e PPC's 1 1685 1444


power s t a t i o n s f o r e l e c t r i c i t y g e n e r a t i o n .
Smaller q u a n t i t i e s a r e supplied t o a f e r t i -
l i z e r p l a n t and t h e PPC's b r i q u e t t i n g f a c t o -
r y . Mining a c t i v i t i e s a r e c o n c e n t r a t e d i n
two a r e a s ( ~ i ~ . 2 )The . f i r s t one i s l o c a t e d
i n N o r t h e r n G r e e c e , c l o s e t o t h e town o f
P t o l e m a i s , where s i x mines a r e under o p e r a -
t i o n a n d new m i n e s a r e p l a n n e d t o o p e n i n
.------:
1-
r------
DEC 1981
1 9 9 1 (planned )

t h e n e a r f u t u r e . The s e c o n d a r e a i s l o c a t e d
i n S o u t h e r n G r e e c e , n e a r t h e town o f Megalo- Figure 1. I n s t a l l e d e l e c t r i c a l power g e n e -
p o l i s , w h e r e two o p e n c a s t m i n e s a r e u n d e r r a t i n g capacity i n Greece, exclu-
exploitation. ding islands.

C o n s i d e r i n g t o d a y ' s s t a t e o f knowledge,
t h e e x t e n s i v e e x p l o r a t i o n program a l r e a d y
u n d e r w a y a n d t h e i n c r e a s i n g demand f o r e l e -
c t r i c a l power, f u r t h e r l i g n i t e d e p o s i t s a r e
e x p e c t e d t o be d i s c o v e r e d a n d e x p l o i t e d .

PROGRAM SCOPE

SIMPTOL i s t h e c o d e name o f a c o m p u t e r
program which s i m u l a t e s t h e mining o p e r a t i o n s
i n a n o p e n c a s t li n i t e m i n e o p e r a t i n g B u c k e t
Wheel E x c a v a t o r s YBWEs), C o n v e y o r s a n d
S t a c k e r s . The program i s s u i t a b l e f o r t h e
c o n d i t i o n s o f Greek l i g n i t e mines and t h e
mining method a p p l i e d t o t h a t .

Based on m a c h i n e r y p a r a m e t e r s and t i m e
s t u d y i n f o r m a t i o n s from e x i s t i n g o p e r a t i o n s ,
t h e u s e r o f SIMPTOL w i l l be a b l e t o s e l e c t
a n d m a t c h BWEs, C o n v e y o r s a n 2 S t a c k e r s t o
f i t mine p r o f i l e a n d m a t e r i a l c h a r a c t e r i -
s t i c s , and meet p r o d u c t i o n r e q u i r e m e n t s .
F u r t h e r m o r e , s i n c e BWEs, C o n v e y o r s a n d
S t a c k e r s a r e j o b - t a i l o r e d m a c h i n e s , t h e ma-
nagement, u s i n g t h e i n f o r m a t i o n s gair-ed from
t h e simulation o f a given deposit, could
a l s o approach the manufacturer with modifi-
c a t i o n s o r a d d i t . i o n a 1 r e q u i r e m e n t s on o f f e -
r e d machinery.

The o t h e r o b j e c t i v e o f t h e p r c g r a m i s t o
a i d production scheduling i n terms of fore-
c a s t i n g t h e monthly and a n n u a l p r o d u c t i o n o f
F i g u r e 2. Major l i g n i t e mining a r e a s .
5 Mtoe : m i l l i o n tonne o f o i l equivalent 1. P t o l e m a i s l i g n i t e b a s i n
(41860 k t l o j o u l e s n e t c a l o r i f i c 2. M e g a l o p o l i s l i g n i t e b a s i n .
v a l u e p e r Kg).
COMPUTER SIMULATION OF MINING OPERATIONS

e a c h e q u i p m e n t a n d o f t h e e n t i r e mine. r a l l e l t o t h e highwall and t h e block i s exca-


v a t e d i n a n number o f b e n c h e s . The h e i g h t o f
e a c h bench i s t h e h e i g h t o f t h e l i g n i t e o r
LIGNITE M I N I N G I N GREECE i n t e r c a l a t e d l a v e r t o be c u t : t h e maximum
b e n c h h e i g h t i s e a p p r o x i m a t e l ~e q u a l t o t h e
The c o n t i n u o u s m i n i n g method i s u s e d i n
B u c k e t Wheel r a d i u s . The w i d t h o f t h e b l o c k
a l l l i g n i t e mines o p e r a t e d by PPC. BWEss i n
a combined o p e r a t i o n w i t h c c n v e y o r b e l t s a n d
i s d e t e r m i n e d by t h e d i g g i n g boom a n d t h e
a r c t h r o u g h w h i c h i t s l e w s . The f a c e i s a d -
s t a c k e r s , have proved s u c c e s s f u l f o r d i g g i n g
vanced s t a r t i n g w i t h t h e e x c a v a t i o n o f t h e
both, overburden and l i g n i t e , and l o a d i n g t h e
t o p bench w h e r e t h e BWE i s trammed f o r w a r d
excavated m a t e r i a l onto s h i f t a b l e conveyors.
a distance s u f f i c i e n t t o f i l l the buckets
A c o n v e y o r ~ e t w o r kt r a n s p o r t s l i g n i t e t o w a r d s
a n d t h e boom s l e w s away from t h e l i n e o f
t h e Power S t a t i o n o r b u n k e r a n d t h e w a s t e t o
advance along a n a r c t o t h e d e s i r e d width.
c r a w l e r mounted boom s t a c k e r s , w h i c h c a s t i t
The m a c h i n e i s moved b o d i l y f o r w a r d i n t h e
o n t o o u t s i d e dumpsor i n t o a mined o u t p a r t
d i r e c t i o n o f advance f o r t h e n e x t c u t u n t i l
o f t h e p i t . Mining t a k e s o n l y a t e m p o r a r y
t h e c r a w l e r s r e a c h t h e b o t t o m bench. S u c c e -
t o l l o f t h e l a n d . Worked-out a n d b a c k f i l l e d
a r e a s a r e reclamated and r e c u l t i v a t e d . For s s i v e l o w e r b e n c h e s a r e mined i n t h e same
manner ( F i g . 4 ) . Upon t h e e x c a v a t i o n o f t h e
t h i s r e a s o n t o p s o i l i s s e l e c t i v e l y mined a n d
b o t t o m bench t h e BWE i s trammed f o r w a r d t o
dumped s e p a r a t e l y .
s t a r t a new b l o c k .
Overburden s t r a t a c o n s i s t s o f f i n e and
coarse c l a s t i c sediments such a s c l a y s .
marls, g r a v e l s , sands and conglomerates. Li-
g n i t e seam c o n s i s t s o f a s e r i f s o f s i n g l e
l a y e r s s e p a r a t e d by s a n d y a n d c l a y e y i n t e r -
c a l a t i o n s . For q u a l i t y reasons t h e a s h
c o n t e n t o f mined l i g n i t e must n o t e x c e e d 3 5 % .
Lignite, according t o t h e a s h content, i s l a -
b e l l e d ~ 1 s" L i g n i t e A " w i t h a n a s h g r a d e b e -
l o w 21% a n d " L i g n i t e B" w i t h a n a s h g r a d e
between 21% a n d 3 5 % . T h e s e two c a t e g o r i e s o f
l i g n i t e , each of which has d i f f e r e n t u t i l i -
z a t i o n , a s w e l l a s t h e occurance o f i n t e r -
calated-wast.e, f o r c e t h e a p p l i c a t i o n o f s e l e -
c t i v e mining o p e r a t i o n .

To e x c a v a t e o v e r b u r d e n a n d l i g n i t e t h e
f u l l b l o c k bench c u t t i n g method i s a p p l i e d
( F i g . 3 ) . The BWE c r a w l e r s a r e b e h i n d a n d p a - F i g u r e 4. Working p l a n f o r BWE d i g g i n g i n
t h e b e n c h c u t t i n g mode.

The e x t r a c t e d m a t e r i a l f l o w s c o n t i n u o u s l y
from t h e d i g g i n g boom v i a a t r a n s f e r p o i n t
and a d i s c h a r g e b e l t system o n t o a s h i f t a b l e
c o n v e y o r l a i n on t h e m i n e ' s b e n c h a n d t h r o u g h
a. p e r m a n s n t . c o n v e y o r s n e t w o r k i s t r a n s p o r t e d
t o t h e dumping f s c i l i t i e s . BWEs, c o n v e y o r s
and s t a c k e r s have c o - o r d i n a t e d c a p a c i t i e s and
the e n t i r e flow route of t h e material i s
interlocked electrically.

F i g u r e 5 shows a s c h e m a t i c c r o s s - s e c t i o n
o f t h e K a r d i a mine w h i c h r e p r e s e n t s a t y p i c a l
Greek l i g n i t e mining o p e r a t i o n .

THE PROGRAM

B a s e d on a work d e s c r i b e d by P a n a g i o t o u 7
SIMPTOL ha: b e e n d e v e l o p e d t o s i m u l a t e m i n i n g
o p e r a t i o n s o f t h e mode p r e s e n t e d a b o v e . T h e
p r o g r a m i s w r i t t e n i n FORTRAN I V f o r u s e w i t h
t h e CYBER 1 7 1 / 8 S y s t e m a t t h e N a t i o n a l T e c h -
n i c a l U n i v e r s i t y o f Athens. It c o n s i s t s o f
s i x i n t e r r e l a t e d s u b r o u t i n e s under t h e names:
READER : r e a d s i n d a t a w h i c h a r e g o i n g t o
b e u s e d by v a r i o u s s u b r o u t i n e s .
F i g u r e 3. The f u l l b l o c k b e n c h c u t t i n g CONTRL : c o n t r o l s t h e s i m u l a t i o n o f t h e
method. equipment i n v o l v e d i n t h e mining
operation.
USE OF COMPUTERS IN COAL INDUSTRY

OVERBURDEN \ u u F?

I INNER
/ DUMP

NNW
- 350 200 A

SS E

F i g u r e 5. Schematic cross-section of t h e K a r d i a o p e n c a s t l i g n i t e mine.

BWES : d e s c r i b e s t h e o p e r a t i o n o f BWEs. G e n e r a l D a t a : Number of m i n i n g s e c t i o n s a n d


s h i f t s t o be s i m u l a t e d , number o f w a s t e dump-
CONVEY : d e s c r i b e s t h e o p e r a t i o n o f c o n - i n g a r e a s , number o f b u n k e r s , s h i f t l e n g t h
veyors and stackers. and time increment f o r the simulation pro-
PROCES :g e n e r a t e s d e l a y s f o r t h e e q u i p - cess.
ment.
BWEs a n d Mine P r . o f i l e D a t a : T h e s e i n c l u d e
PRINTR : p r i n t s o u t t h e r e s u l t s o f t h e s i - s o i l c h a r a c t e r i s t i c s , m i n e d i m e n s i o n s , BWEs
- -
mulation. s p e c i f i c a t i o n s , a v a i l a b i l i t y and time study
F i g u r e 6 shows t h e b l o c k d i a g r a m o f t h e p r o - data.
gram.
: Number o f s e -
Program i n p u t s a n d o u t p u t s . c t i o n and erouo b e l t s i n t h e svstem, capaci-

Input parameters a r e c l a s s i f i e d a s
r
ty lenghtuand' s p e e d of e a c h b k t , a v a i l a b i -
l i t y o f b e l t s a n d down-time; d i s c h a r g i n g r a -
follows : t e , a v a i l a b i l i t y a n d down-time o f s t a c k e r s .

S u b r o u t i n e PRINTR p r i n t s o u t t h e r e s u l t s

-67
o f t h e s i m u l a t i o n which i n c l u d e production
PROGRAM s t u d y f o r e a c h m a t e r i a l e x c a v a t e d ignite
A , L i g n i t e B and Waste), a c t u a l capacity.
power consumption and r a t i n g o f d i g g i n g ,
s l e w and c r a w l e r motors, t i m e s t u d y and de-
l a y s o f t h e machinery

S u b r o u t i n e BWES.

S u b r o u t i n e BWES, u s i n g known e q u a t i o n s ,
BWES d e s c r i b e s t h e o p e r a t i o n o f BWEs a c c o r d i n g t o
t h e f u l l b l o c k b e n c h c u t t i n g m e t h o d . The p a -

1 t s s a g e o f a b u c k e t t h r o u g h t h e bench h e i g h t .
t h e s l e w i n g m o t i o n o f t h e d i g g i n g boom, t h e
crowding a c t i o n o f t h e c r a w l e r s and t h e ad-
PROCES v a n c e o f t h e machine from bench t o bench a r e
s i m u l a t e d by u s i n g t h e p r o c e d u r e d e s c r i b e d
by V e n k a t a r a m a n i a n d M a n u l a , 1 9 7 0 1 0 . A t t e n -
t i o n h a s been d i r e c t e d toward t h e d i g g i n g
action, since digging force required i s the
v d e c i d i n g f a c t o r i n t h e d e s i g n o f a BWE.
D i g g i n g p o w e r r e q u i r e d i s c a l c u a t e d by
B
PRINTR u s i n g t h e f o r m u l a ( ~ a s ~ e 1r 9, 6 4 ),

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COMPUTER SlMULATlON OF MlNlNC OPERATIONS

Table 1

Input data required f o r the application

Farameter

General Data
Number o f m i n i n g s e c t i o n s 1
Number o f s h i f t s t o b e s i m u l a t e d 7
Number o f w a s t e dumping a r e a s 1
Number o f b u n k e r s 2
Time i n c r e m e n t , s 2
Shift length, s 28800
BWEs a n d M i n i n g P r o f i l e D a t a
Number o f d i f f e r e n t s o i l t y p e s i n t h e s e c t i o n 3 (waste=l, L i g n i t e A=2. L i g n i t e ~ = 3 )
Bucket f i l l i n g c a p a c i t y , % o f nominal 0.8 (waste) 0.9 ( ~ i ~ n i A t )e 0 . 9 ( ~ i ~ n i Bt )e
Specific cutting resistance, ~g(cm 75 60 60
Number b u c k e t d i s c h a r g e s . min ' 62 62 62
Swell f a c t o r 0.7 0.8 0.8
Number o f BWEs i n s e c t i o n 1
C r a w l e r s p e e d , m/s 0.11
L e n g t h o f d i g g i n g boom, m 28
Nominal c a p a c i t y o f b u c k e t , m 3 0.6
Number o f b u c k e t s 10
Wheel d i a m e t e r , m 7.5
Depth o f b l o c k , m 15
Weight o f s u p e r s t r u c t u r e , k g 688000
T o t a l wight, kg 91 8000
Rolling resistance 0.02
Slope of s e c t i o n ' s f l o o r % 2
C o e f f i c i e n t of f r i c t i o n a t b a l l r a c e 0.03
Radius o f b a l l r a c e , m 3.5
Slew a n g l e , l e f t 80 O
Slew a n g l e , r i g h t 20°
A v a i l a b i l i t y o f BWE 0.60
Mean d o w n - t i m e , s 300
Slope of s e c t i o n ' s bench 600
Number o f b e n c h e s t o be c u t h
Height o f each bench, m 3.50 1 . 50 1.30 5.80
Type o f m a t e r i a l i n e a c h b e n c h 1 2 1 3
Density o f m a t e r i a l ( ~ o n n e / m j ) 2.0 1.4 2.0 1.4
Conveyors and S t a c k e r Data
Belt Availability Length, m C a p a c i t y , m3/s Speed, m / s

Mean down t i m e f o r b e l t s , s
Discharging r a t e o f Stacker, tonne/s
Mean down t i m e f o r S t a c k e r , s
Availability of Stacker
USE OF COMPUTERS IN COAL INDUSTRY

REFERENCES

Anon., 1 9 8 2 , " 1 9 8 0 E n e r g y S t a t i s t i c s
Y e a r b o o k " , E u r o s t a t , EEC, Luxembourg.

Anon., 1 9 7 9 , " I n t e r n a t i o n a l M a t h e m a t i c a l
a n d S t a t i s t i c a l L i b r a r y , L i b r a r y 3 . IMSL
Inc., Jan.

B a n d o p a d h y a y S . , Ramani R.V., a n d Manula


C.B., 1 9 8 1 , " A C o m p u t e r S i m u l a t i o n Model
f o r a S u r f a c e C o a l Mine", Bulk S o l i d s
H a n d l i n g , V o l . 1 , No.1, F e b . , p p . 1 2 9 - 1 3 5 .

C o e r g e n H. a n d F i e b i g W . , 1 9 8 0 , " L i g n i t e
Mining i n t h e P t o l e m a i s Region, G r e e c e u ,
Mining Magazine, Feb. pp.126-139.

Mani M.S., 1 9 6 6 , " D e s i g n F e a t u r e s o f


B u c k e t Wheel E x c a v a t o r s " , J o u r n a l o f
Mines, M e t a l s a n d F u e l s , Mar., pp.71-79.

P a n a g i o t o u C.N., 1 9 7 8 , " A s t u d y t o I n -
c r e a s e t h e E f f i c i e n c y o f BWEs i n K a r d i a -
P t o l e m a i s L i g n i t e Mine", D i p l . T h e s i s ,
N.T.U. o f A t h e n s , 102 pp.

Panagiotou G.N., 1 9 7 9 , "Computer S i m u l a -


t i o n o f t h e M i n i n g O p e r a t i o n s i n a n Open-
c a s t L i g n i t e M i n e " , M.Sc. T h e s i s , U n i -
v e r s i t y o f N e w c a s t l e u p o n T y n e , 5 8 pp.

R a s p e r L. , 1 9 6 4 , " S t a n d d e r E n t w i c k l u n g
d e r S c h a u f e l r a d b a g g e r i n t h e Bundes-
r e p u b l i c D e u t c h l a n d " , B r a u n k o h l e , warme
und E n e r g i e , V o l . 1 6 , Nov., p p . 4 5 7 - 4 7 1 .

R a s p e r L . , 1 9 7 5 , "The B u c k e t Wheel Ex-


c a v a t o r " , T r a n s Tech P u b l i c a t i o n s , pp. 75.

V e n k a t a r a m a n i R . , a n d M a n u l a C.B., 1 9 7 0 ,
" C o m p u t e r S i m u l a t i o n o f B u c k e t Wheel Ex-
c a v a t o r s " , T r a n s . SME-AIME, V o l . 2 4 7 .
S e p . , pp. 274-280.

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