Pit, Haul Fleet, and Crushing Optimization

KCSA ‘18

Tony Gianni Trimble LOADRITE

Introduction

• Eastern NA Sales Manager Trimble Loadrite• 5 years as Technical Support Engineer• Hundreds of quarries around the world• Belt scales, plant integration, online reporting

Today’s Objectives• What is the Connected Quarry? • What technology is available? • How can operations be more efficient? • How can reports be a valuable tool? • How can my processes be improved? • Where can I reduce costs and improve profit?

Connected Quarry• Measurement

o Real time link and visibility of all three zoneso Extractiono Processingo Loadout

• Staying Connected to your Quarry

Connected QuarryPit loading:Measure loading and haul truck productivity. Optimize haulage.Measure Blast performance

Processing / Production:Measure total production. Tonnage per product and specific stockpile tonnage. Downtime reporting and monitor plant utilisation.

Load-out management:Load your customers trucks more accurately, eliminate overloading , reduce waiting time, improve safety.Fully integrated solution with site ERP or dispatch systems.

Available Technology• On-board Weighing Technology

o Pit Loader Scaleso Haul Truck Monitoring Systemso Primary Conveyor Scaleso Final Product Conveyor Scaleso Yard Loader Scales

• Improved Data Transfer• Cloud Based Reporting Software

Cloud Based Reporting• Near Real Time Insight and Visibility

o Fix Today’s Problems• Increased Accessibility• Operational Analysis

Targeted Operational Improvements • Throughput per hour

o Faster cycle times reduces the hours needed to achieve a certain task or output o Reduced machine hours reduces fuel cost, maintenance cost, repairs, capital depreciation, for the same

amount of output

• Cost per hour o Treating equipment better reduces maintenance costs, regardless of the output / hr o Operating a machine properly can reduce fuel cost and maintenance cost for the same productive output

• Idling, running empty o Like idling for mobile equipment, “black belt time” in crushing and screening

• Reduce wasted material o Sell as much as you can of what you make

• Value of service o Better customer service leads to more business and better pricing

Sample Quarry Operation• Production:

o 900,000 ton theoretical capacity o Selling 730,000 tons per year, at $10/ton

• Fleet: o Pit: 1 Drill (1 shot/ 2 wks), 1 excavator, 3 Haul Trucks o Processing: 3 crushers, 10 belts o Loadout: 4 Loaders, 1 water truck, 1 weigh bridge

• Other parameters: o 17 staff o 11 months/yr, 5 days/wk, 8 hrs/day operation

Extraction• Pit loader scales optimize the

load in each trucko By loading closer to optimal

weight, avoid under loaded trucks, and reduce the number of cycles

o Minimize fuel consumption and maintenance costs

o Measure blast efficiency

Extraction• Cloud Based Performance

and Availability Management

Extraction• Not all operators

are the same• Load out

management system helps to:o Identify ‘A’ operatorso Assist ‘B’ and ‘C’

operators

Extraction• Haul trucks activity

o Loading timeo Haul timeo Queuing time

• Shows machinery availability/performanceo Identifies bottlenecks, bunching/line-

upso Empowers fleet managers to make

improvements that affect production during the shift

• Higher total throughput

Extraction• Automated product totals provides

accurate production figures• Avoid tabulating load sheets• Highlights material movement issues• Increased Safety

Extraction• Overall summary of fleet

performance• Average haul truck loading

time• Compare Truck TPH to

Primary TPH to determine feeding efficiency

• Speedingo Increased safetyo Increased production

Customer feedback: Reduction in cycle times

• Monitoring system data helped identify issues causing longer cycle times.

• Dumping time issues caused by waiting for traffic light.

• Change in practice to call for lights once in position.

• Achieved 50% reduction in dump time.

• Time saving of 1 hour per day.

Shap Beck Quarry : Pit OptimizationShap Beck Quarry •X2350 Excavator Scale •Reporting software

Eighty (80) day Payback •Purely from optimizing haulage Additional value from: •Better management of blasting contractors •Hard data to right-size equipment

Recommended to rollout on largest global sites

“Having Loadrite systems and reports was like putting reading glasses on. We could see and analyze every detail of our operation.”-Chris Herbert, plant supervisor Shap Beck Quarry, UK

Extraction Improvements

• Task Productivity o Reduce the number of truck cycles o Compress operating costs

• Process productivity o Reduce truck cycle time

• Monitor blast yields • Reduce inventories and re-handling

Cost improved by 10 cents/ton, With a system that costs about 2.2 cents/ton (over 7 years)

ROI: Extraction

Additional Benefits: 1.Accelerate Operator learning curve ! Achieve more than the above, or faster 2.Improved Safety

1. Ensure trucks are loaded appropriately for the circumstances ! priceless

Processing• Installation of belt scales

to monitor flow of product through the system

• Visibility into plant operations

• Process Managemento Over/under loadingo Stop timeo Black belt time

Processing• Identify bottle necks and

pinch points• Undersized equipment• Monitor wear parts against

tons processed• Identify waste• Energy used per ton• Cost analysis• Help with inventory accuracy

at month/quarter and year-end

Processing• Review real plant availability

information • Run time, black-belt time,

scheduled time• Track down time• Belt start and stop times• First and last time the belt

was loaded• Immediate efficiency

feedback

SiteBeltReport Period

08:49

07:17

01:3217.4% Start time 07:10 Stop time 16:5011 Time of first load 07:55 Time of last load 16:40

Black belt %Number of belt stops

Conveyor Performance Report

Yesterday

Rock Quarry

PrimaryRun time

Run time loaded

Black belt run time

Primary

0

2

4

6

8

10

07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00Stopped time Black belt time Loaded time

Minutes

83%Run time loaded

Black belt run time

Processing• Instantaneous Operational

Datao Rate (TPH)o Total Tonso Belt Status

• Zeroing of Scaleso Maintains highest level of accuracy

• Graphical trends of production

• Down time event coding/tracking

Processing• Measuring production

helps:o Ensure stockpile

inventory accuracyo Communicate daily,

weekly, monthly targets• Create connection

between process and product

Effect of empty run (black belt) time

Regional Production MonitoringWhat was the solution?• Installation of belt scales on each site after

the primary crusher• Various pieces of data communication

infrastructure to provide the best solution• Access to Cloud Based Reports by

regional and site management

Internet

Regional Production Monitoring

Solution •Installation of belt scales on each site after the primary crusher •Various pieces of data communication infrastructure to provide the best solution for each site, incl. Ethernet, radio and cellular modem •Access to cloud based reports by regional and site management

Benefits •Monitoring of black belt time after each primary crusher; operating the plant only when material has to be processed •Monitor the performance of all sites with the same type of scale •Consolidate all data in one single data base •Reduce software and hardware variations

Overall reduction in operating cost, reduction in power consumption and maintenance and increase in management productivity by remote monitoring of all sites

Cost improved by 9 cents/ton,With a system that costs about 1.5 cents/ton (over 7 years)

• 5% reduction in black belt time

• 1% reduction in maintenance costs

• Reduced downtime events

ROI: Processing Summary

Additional Benefits 1.Improved Employee Satisfaction

o Less manual reporting, less data re-entry  → hiring and training costs

2.Improved Safety o Keep people away from heavy machinery when not necessary  →  priceless

Performance metrics improved

• Throughput per hour, cycle times • Utilization • Cost per hour • Sales / Extraction ratio • Customer Satisfaction

Financial Benefit Achieved

Cost improved by 37 cents/ton, With an investment of 5.2 cents/ton (over 7 years)

Video

Questions?

THANK YOU!