bwe ops - simulation

8/8/2019 BWE Ops - Simulation

1/8

COMPUTER SIMULATION OF THE M I N I N G OPERATIONS I NOPENCAST L I GN I T E MINES OPERATING BWES, CONVEYORS

AND STACKERS

G . N . PANAGIOTOUDEPARTMENT OF M I N I N G ENGINEERING

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

ABSTRACTSIMPTOL, a compu ter s i m u l a t i o n program w r i t t e n i n FORTRANI V f o r u s e w i t h C yber 1 7 1 / 8 System a t t h e N a t i o n a l T e ch -n i c a l U n i v e r s i t y o f A th en s, d e s c r i b e s t h e m in in g o p e r a -t i o n s i n a n o p e n c a s t l i g n i t e m in e o p e r a t i n g B uc ke t WheelE x c a v a t o r s , C on ve yo rs an 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 eo f t h e p ro gr am i s t o a i d management i n t h e s e l e c t i o n o fa BWE-Conveyor-Stacker Sys tem f o r a g iv en l i g n i t e d e p o s i ta nd e qu i p m e nt l a y o u t . Much i n f o r m a t i o n c a n b e g a i n e d f ro mt h e pro gr am w i t h p r o p e r m a n i p u la 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 in in 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 qu ip -ment s p e c i f i c a t i o n s and a v a i l a b i l i t i e s and t im 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 pr og ra m i s t o a i d p r o d u c t io ns ch e du l i n g i n t e rm s o f f o r e c a s t i n g p r o du c t i o n r a t e s o ft h e s y s te m . The p ro gr am h a s b ee n a p p l i e d t o K a r d ia l i g n i t emine t o e v a l u a t e i t s u s e fu l n es s t o r e p r e s e n t t h e a c t u a ls i t u a t i o n o f t h e s ys te m b e i n g s i m u l a t e d .


2/8

USE OF COMPUTERS IN COAL INDUSTRY

INTRODUCTIONW it h a p r o d u c t i o n o f 1 2 0 . 5 toe*, i n 1 98 0,

l i g n i t e m in in g 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 or ld p r c ~ d u c t i o no f m i n e ra lf u e l s . The en er gy c r i s i s f o r c e d t h e e x pl o r a -t i o n a nd e x p l o i t a t i o n o f l ow c a l o r i f i c v a lu ec o a l s - l i g n i t e s - u n d e r t h i c k o v er b u r d en m a ss e s,i n o r d e r , n a t i o n s w i t h su ch r e so u r c e s , t ob eco me m or e i n d e p e n d e n t o f o i l i m p o r t s .

G r ee ce , i n 1 98 0, ~ r o d u c e d .0 toe' w h i c hr e p r e s e n t t h e 2 .5 % o f t h e w o r l d p r o d u c t i o no r t h e 9 . 4 % o f EEC p r o d u c t i o n . T he i m p o r t -a n c e o f l i g n i t e i n me e ti n g Gr e e ce ' s e n er g yn e e d s i s o b v i o u s fr om F i g u r e 1 . T he s t a t e -o wn ed P u b l i c P ow er C o r p o r a t i o n ( P PC ) o p e r a -t e s t h e m a j o r i t y o f l i g n i t e d e p o s i t s ; t h r e es m a l l d e p o s i t s a r e m in ed b y p r i v a t e c ompa-n i e s . L i g n i t e i s m a in l y b u r n t i n t h e P PC 'sp ow er 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 .S m a l l e r q u a n t i t i e s a r e s u p p l i e d t o a f e r t i -l i z e r p l a n t a nd t h e PP C' s b r i q u e t t i n g f a c t o -r y . M in i ng a c t i v i t i e s a r e c o n c e n t r a te d i ntwo a r e a s ( ~ i ~ . 2 ) .he f i r s t o n e i s l o c a t e di n N o r t h er n G r ee c e , c l o s e t o t h e town o fP t o l e m a i s , w h e re s i x mi n es a r e u n d e r o p e r a -t i o n a nd new m in es a r e p l a n n e d t o o p en i nt h e n e a r f u t u r e . T he s ec o nd a r e a i s l o c a t e di n S o u t he r n G r e e ce , n e a r t h e t ow n o f M eg al o- F i g u r e 1 . I n s t a l l e d e l e c t r i c a l p ow er g en e-p o l i s , w h er e two o p e n c a s t m i n es a r e u n d e r r a t i n g c a p ac i t y i n G r ee ce , e x cl u -e x p l o i t a t i o n . d i n g i s l a n d s .

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SIMPTOL i s t h e c o d e na me o f a c o m p u t e rp r og ra m w hi ch s i m u l a t e s t h e m i n i n g o p e r a t i o n si n a n o p en c as t li n i t e mi ne o p e r a t i n g B u ck e tW he el Ex c a va t o r s YBWEs), C on ve yo rs a ndS t a c k e r s . T h e p r o gr a m i s s u i t a b l e f o r t h ec o n d i t i o n s o f G re ek l i g n i t e m in es a nd t h em i ni n g m et ho d a p p l i e d t o t h a t .

1 4315I r------11 II I I1 2 5 1 3 1 1 1685 1 4 4 4

- DEC 1981r - - - - - -------:9 9 1 (p lanned )

B a se d o n m a ch i n e r y p a r a m e t e r s a n d t i m es t u d y in f o r m a t i o n s f ro m e x i s t i n g o p e r a t i o n s ,t h e u se r o f SIMPTOL w i l l be a b l e t o s e l e c tan d match BWEs, C onv eyo rs a n 2 S t a c k e r s t of i t m ine p r o f i l e a nd m a t e r i a l c h a r a c t e r i -s t i c s , a nd me et p r o d u c t i o n r e q u i r e m e n ts .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 dS 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 in e s , t h e ma-n a ge m en t , u s i n g t h e i n f o r m a t i o n s g a ir - ed f ro mt h e s i m u l a t i o n o f a g i v en d e p o s i t , c o u l da l s o a p pr o ac h t h e m a n u f a c t u r e r w i t h m o d i f i -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 o n o f f e -r e d m a c h i n er y .

The o t h e r o b j e c t i v e o f t h e p rc gr am i s t oa i d p r o du c t i o n s c h e d u l i n g i n t e r m s o f f o r e -c a s t i n g t h e m o nt h ly a nd a n n u a l p r o d u c t i o n o f5 Mtoe : m i l l i o n t o nn e o f o i l e q u i v a l e n t(4 186 0 k t l o j o u l e s n e t c a l o r i f i c

v a l u e p e r K g) .

F i g u r e 2. M aj or l i g n i t e m i ni n g a r e a s .1. P t ol e ma i s l i g n i t e b as i n2 . M e g a lo p ol i s l i g n i t e b a s in .


3/8

COMPUTER SIMULATION OF MINING OPERATIONS

e a c h eq u ip m en t an d o f t h e e n t i r e m in e.

LIGNITE M I N I N G I N GREECEThe c on t i n uous mi n i ng me t hod i s u s ed i na l l l i g n i t e mi n es o p e r a t e d b y PPC. BWEss i n

a co mb in ed o p e r a t i o n w i t h c c n v e y or b e l t s a n ds t a c k e r s , h av e p r ov e d s u c c e s s f u l f o r d i g g i n gb o t h, o v er b ur d en an d l i g n i t e , a n d l o a d i n g t h ee x c av a t ed m a t e r i a l o n t o s h i f t a b l e c o n v ey o r s.A co nv ey or ~ e t w o r k r a n s p o r t s l i g n i t e t ow ar dst h e P ow er S t a t i o n o r b u nk e r an d t h e w a s t e t oc r a w l e r mo u nt ed boom s t a c k e r s , w h i ch c a s t i to n t o o u t s i d e d um pso r i n t o a m in ed o u t p a r to f t h e p i t . M in in g t a k e s o n l y a t e m p o r ar yt o l l o f t h e l an d . W or ke d- ou t a n d b a c k f i l l e da r e a s a r e re c la m a te d an d r e c u l t i v a t e d . F o rt h i s r ea so n t o p s o i l i s s e l e c t i v e l y m in ed a n ddumpe d se pa ra t e l y .

r a l l e l t o t h e h ig h wa ll a n d t h e b lo ck i s e x c a -v a t e d i n a n n um be r o f b e n ch e s . T he h e i g h t o fe a c h be nc h i s t h e h e i gh t o f t h e l i g n i t e o ri 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 maximumb en ch h e i g h t i s e a p p r o x i m a t e l ~ q u al t o t h eB u c k e t W he el r a d i u s . T he w i d t h o f t h e b l o c ki 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 ea r c t h r o u g h w h ic h i t s l e w s . T h e f a c e i s a d -v an ce d s t a r t i n g w it h t h e e x c a v a ti o n o f t h et o p b e n c h w h e r e t h e BWE i s t ra mm ed f o r w a r da d i s t a n c e s u f f i c i e n t t o f i l l t h e b u c k e t sa n d t h e b oom s l e w s a wa y fr om t h e l i n e o fa dv a nc e a lo n g a n a r c t o t h e d e s i r e d w i d th .The machine i s moved b o d i l y f o r w a r d i n t h ed i r e c t i o n o f a dv an ce f o r t h e n ex t c u t u n t i lt h e c r a w l e r s r e a c h t h e b o t to m be nc h. S u c c e -s s i v e lo w e r b e n c h es a r e mi ne d i n t h e sa mem a n n e r ( F i g . 4 ) . Upon t h e e x c a v a t i o n o f t h ebo tto m b ench t h e BWE i s t ra mmed forw a rd t os t a r t a new b l o c k.

O ve rb ur de n s t r a t a c o n s i s t s o f f i n e a n dc o ar s e c l a s t i c s e d im e nt s s u c h a s c l a y s .m a r l s , g r a v e l s , s a n d s a n d c o n g l o m e r a te s . L i -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 el a y e r s s e p a r a t e d by s a n dy a nd c l a y e y i n t e r -c a l a t i o n s . F or q u a l i t y r e a s on s t h e a s hc o n t e n t o f m in ed l i g n i t e m us t n o t e x c ee d 3 5 % .L i g n i t e , a c c o r d in g t o t h e a s h c o n t e n t , i s l a -b e l l e d ~ 1 s L i g n i te A " w i t h a n a s h g r a d e b e-l o w 2 1 % a n d " L i g n i t e B " w i t h a n a s h g r a d eb et we en 2 1 % a n d 3 5 % . T h e s e t wo c a t e g o r i e s o fl i g n i t e , e ac h o f w hic h h a s d i f f e r e n t u t i l i -z a t io n , a s w e l l a s t h e o cc ur an ce o f i n t e r -c al at ed - wa st .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 m i ni n g o p e r a t i o n .

To e x c a v a te o v er b u r de n a nd l i g n i t e t h ef u l l b l o c k b en ch c u t t i n g m eth od 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 nd p a - F i g u r e 4. W or ki ng p l a n f o r BWE d i g g i n g i nt h e b e n ch c u t t i n g mode.

F i g u r e 3. The f u l l b lo c k b en ch c u t t i n gmethod.

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 yf ro m 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 ta nd a d i s c h a rg e b e l t s y st em o n to a s h i f t a b l ec o n v ey o r l a i n on t h e m i n e ' s b e nc h a n d t h r o u g ha. pe rma nsn t . c onve yors ne t work i s t r a n s p o r t e dt o t h e d um pin g f s c i l i t i e s . BWEs, c o n v e y o r sa nd s t a c k e r s h av e c o - o r d in a t e d c a p a c i t i e s a n dt h e e n t i r e f l o w r o u t e o f t h e m a t e r i a l i si n t e r l o c k e d e l e c t r i c a l l y .

F i g u r e 5 s ho ws a s c h e m a t i c c r o s s - s e c t i o no f t h e K a rd i a m in e w hi ch r e p r e s e n t s a t y p i c a lG re ek l i g n i t e m in i ng o p e r a t i o n .

THE PROGRAMB a s e d o n a wo rk d e s c r i b e d b y P a n a g i o t o u 7SIMPTOL ha: be e n de ve l op e d t o s i m ul a t e mi n i ngo 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 ve . T hep r og r am i s w r i t t e n i n FORTRAN I V f o r u s e w i t ht 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 A t h en s . I t c o n s i s t s o fs 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 u nd er t h e n am es :READER : r e a d s i n d a t a w hi ch a r e g o i n g t ob e u s e d by v a r i o u s s u b r o u t i n e s .CONTRL : c o n t r o l s t h e s i m u la t i o n o f t h ee q ui p me n t i n v o l v e d i n t h e m i n in go p e r a t i o n .


4/8

USE OF COMPUTERS IN COAL INDUSTRY

OVERBURDEN \ u u F ?

I I NNER/ DUMP- 350 200ANNW SS E

F i g u r e 5. S c h em 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 o p e n c a s t l i g n i t e m in e.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.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 -v e y o r s a n d s t a c k e r s .PROCES : e n e r a t e s d e l a ys f o r t h e e q ui p -men t .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 -

m u l a t i o n .F i g u r e 6 s h ow s t h e b l o c k d i a g ra m o f t h e p r o -gram.P ro gr am i n p u t s a n d o u t p u t s .

I n pu t p a ra m et e rs a r e c l a s s i f i e d a sf o l l o w s :

PROGRAM-67

G e n e r a l D a t a : Number o f m i n i n g s e c t i o n s an ds h i f t s t o b e s i m u l a t e d , n um be r o f w a s t e dump-i n g a r e a s , number o f b u n ke r s, s h i f t l e n g t ha n d t i m e i n c r e me n t f o r t h e s i m u l a t i o n p r o -c e s s .BWEs and Mine Pr .o fi le D a t a : T h e se i n c l u d es o i l c h a r a c t e r i s t i c s , mine di me ns io ns , BWEs-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 a nd t im e s t u dyd a t a .

: Number of s e -c t i o n a nd e r o u o b e l t s i n t h e s v st e m, c a p ac i -t y l e ng h tu a nd ' s p e ed o f 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 nd do wn- ti me ; d i s c h a r g i n g r a -t e , a v a i l a b i l i t y a n d down-t ime 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 so f t h e s i m u l a t i o n w hi ch i n c l u d e p r o d uc t i o ns t u d y f o r e a c h m a t e r i a l e x c av a t ed ignite

A , L i g n i t e B a n d W a st e ), a c t u a l c a p a c i t y .p ow er c o n s u m p ti o n a n d r a t i n g o f d i g g i n g ,s l e w a nd c r a w l e r m o t or s , t i m e s t u d y a n d d e -l a y s o f t h e m ac h in e rySu br ou t i ne BWES.

F i gu re 6 . The b l oc k d iag ram o f SIMPTOL.

BWES S u b r o u t i n e BWES, u s i n g known e qu at io ns ,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

1 t t h e f u l l b l o c k b e nc h c u t t i n g m et ho d. T he p a -s s a g e o f a b u c k e t t h r o u g h t h e b en ch 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 ePROCES c r ow d in g a c t i o n o f t h e c r a w l e r s a nd t h e a d -v a n c e o f t h e m a c hi n e f ro m b e nc h t o b en ch a r es i m u l a t e d by u s i n g t h e p ro c e d u r e d e s c r i b e d

v

by V enk a ta r ama n i and M anula , 197010 . A t te n -t i o n h a s b e en d i r e c t e d t o wa rd t h e d i gg i n ga c t i o n , s i n c e d i g g i n g f o r c e r e q ui r e d i s t h ed 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 ow er r e q u i r e d i s c a l c u a t e d by

PR INTR Bs in g t h e f o r m u l a ( ~ a s ~ e r ,9 64 ),


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