Investigation of the width of the entry of an excavator when loading a mobile crushing plant in the conditions of the Angren coal mine of Uzbekistan

This article presents the results of studies to establish the optimal entry width for an excavator working in conjunction with mobile crushing plants in the development of overburden of the Angren open pit. According to the results of the research, an analytical relationship was established to determine the maximum productivity of the mining system “excavator-mobile crushing-reloading-conveyor complex” with cyclical-flow technology. A structural diagram has been developed that allows you to select the type and determine the main technological parameters of the equipment with the selected criteria for evaluating the effectiveness of the complexes. It has been established that the choice of equipment for conveyor lines should be carried out taking into account the mutual influence of adjacent technological links of the central heating systems, including the influence of the excavator-crushing and crushing-conveyor complexes on the efficiency of their mutual functioning within the framework of the adopted system as a whole. A functional graphical dependence of the excavator performance on the face width was obtained, taking into account the relationship of all technological parameters of the face. It has been established that the maximum excavator productivity of 1478.1 m3/hr is achieved with an excavator entry width of 17.4 m for the conditions of the Angren open pit. The resulting schedule makes it possible to assess the possibility of increasing the operational performance of single-bucket shovel excavators under various conditions of work, as well as to continue the optimization of excavation.

ANALYSIS OF LOGISTIC RISKS OF RAILWAY TRANSPORT OF THE MINING AND CONCENTRATING PLANT UNDER CONDITIONS OF INCREASING PRODUCTION VOLUMES OF FINISHED PRODUCTS

Purpose. In modern conditions, the problem of increasing the efficiency of the railway transport of industrial enterprises is very urgent, and, first of all, this applies to enterprises of the metallurgical and mining industry, which are the largest recipients and consignors of goods by the railways of Ukraine. In this regard, the purpose of the study is to develop measures to increase the throughput and carrying capacity of the railway infrastructure of a mining enterprise in the context of an increase in the transportation of raw materials. Methods. The analysis of the technical equipment and technology of the railway transport of a large mining and processing plant in Ukraine was carried out using the methods of graphical analytical modeling. Results. The track development of the mining and processing plant ensures the delivery of iron ore from the quarry to the crushing and processing plant. The plant is presented as a system for transporting raw materials from loading points to unloading points, in which the process of its consumption is uniform (unloading ore on the tracks of a crushing plant), and the process of its replenishment is uneven (loading ore at loading points). Smoothing the uneven supply of raw materials between the points of loading and unloading provides the track capacity of the station adjacent to the crushing plant. The carrying capacity of the existing railway infrastructure of the plant does not ensure the mastery of the estimated volumes of transportation of raw materials. Analysis of the results of graphical modeling of the mining and processing plant showed that the limiting elements are the processing capacity of the crushing plant and long distances between the loading points and the abutment station. Organizational and technical solutions are proposed to increase the throughput of the railway infrastructure of the mining and processing plant. Practical significance. The results obtained can be used in the implementation of recommendations aimed at increasing the efficiency of the functioning of the railway transport of the mining and processing plant in conditions of an increase in the volume of transportation of raw materials.

SIMULATION-DRIVEN DEVELOPMENT FOR COARSE COMMINUTION PROCESS - A CASE STUDY OF GEITA GOLD MINE, TANZANIA USING PLANTSMITH PROCESS SIMULATOR

A comminution process is a material size reduction and separation process which is primarily used in the aggregates and the minerals processing industry. Knowledge related to equipment’s operation, raw material properties, operational strategies, control system, maintenance, etc. is needed to design a capable plant. New needs are arising from the industry for existing operational crushing plants such as investigation for improvements, upscaling, and downscaling of the capacity. The paper presents an application of simulation-driven development for a crushing plant in an existing gold processing plant. Due to the change in ore characteristics and the need for optimizing the cost of operation, it is required to investigate the opportunities for improvement and alternative options for downscaling the capacity of the plant. A systematic process for configuring, developing, and evaluating alternative concepts using a process simulation tool is presented. The results show the process of generating knowledge for alternative crushing plant operation settings and how the choices can be selected and eliminated using boundary conditions. The evaluation presents possible improvements and alternative concepts with their opportunities and pitfalls.

Image Process of Rock Size Distribution Using DexiNed-Based Neural Network

In an aggregate crushing plant, the crusher performances will be affected by the variation from the incoming feed size distribution. Collecting accurate measurements of the size distribution on the conveyors can help both operators and control systems to make the right decisions in order to reduce overall power consumption and avoid undesirable operating conditions. In this work, a particle size distribution estimation method based on a DexiNed edge detection network, followed by the application of contour optimization, is proposed. The proposed framework was carried out in the four main steps. The first step, after image preprocessing, was to utilize a modified DexiNed convolutional neural network to predict the edge map of the rock image. Next, morphological transformation and watershed transformation from the OpenCV library were applied. Then, in the last step, the mass distribution was estimated from the pixel contour area. The accuracy and efficiency of the DexiNed method were demonstrated by comparing it with the ground-truth segmentation. The PSD estimation was validated with the laboratory screened rock samples.

ABOUT THE CAPACITY OF THE RECEIVING HOPPER OF THE QUARRY CRUSHING PLANT

The results of the analysis of the application of the methods of the theory of queuing for calculating the capacity of the receiving hopper of an open-pit crushing plant used in combination with a combined automobile-conveyor transport are presented. An analytical expression is given for calculating the capacity of the bunker, taking into account the minimum possible duration of the interval between unloading dump trucks into the bunker. The capacity of the receiving hopper of the crushing plant with a capacity of 4300 t / h was determined when working with dump trucks with a carrying capacity of up to 180 tons.

Application of Numerical and Block Geomechanical Modelling to Determine Parameters of Large-Section Chambers

The study is exemplified by complex workings of a main ore pass that include a variety of underground structures, usually with unique dimensions which depend on the function and size of the equipment placed. The technical solutions for the underground crushing plant and associated structures envisage construction of chambers with the height of up to 35 m and the width of up to 20 m at the depths exceeding 800-1000 m. Such conditions call for a closer attention to be paid to the mine support parameters, especially the bolting depth. A block geomechanical model was designed in the Micromine Mining Software for the rock mass of the new main ore pass. Geotechnical boreholes logs and results of physical and mechanical rock tests were used as the input data for the model. Four domains were identified in the block geomechanical model for subsequent numerical modelling. A 3D model of the stress-and-strain state of the rock mass was made using the CAE Fidesys software based on the Micromine wire-frame model of the main ore pass. The history of the rock mass incremental loading was reconstructed for correct simulation of its stress-and-strain state. Prior to the excavation, the rock mass is pre-stressed by the weight of the rock strata. The excavation phase was then simulated in the stepwise manner. An array of points with the values of maximum principal stresses was downloaded from the numerical model post-processing program and interpolated into the block geomechanical model to refine the SRF parameter of the Barton's Q rating. Based on the obtained Q values, the mine support parameters for chambers were determined using the Barton, Hutchinson and Potvin empirical methods.

ANALISIS PENCAPAIAN TARGET PRODUKSI CRUSHER PADA CRUSHING PLANT PT BANUA TAPIN MANDIRI KABUPATEN TAPIN PROVINSI KALIMANTAN SELATAN

PT Banua Tapin Mandiri merupakan perusahaan yang bergerak dibidang jasa penambangan dan pengolahan batubara dan penjualan. Usaha untuk meningkatkan kualitas batubara memerlukan kegiatan pengolahan batubara (coal processing plant) serta penjualan batubara. Pertimbangan pengembangan usaha datang dari pemikiran bahwa Indonesia memiliki potensi sumber daya batubara yang cukup besar.Metode penelitian yang digunakan untuk menganalisis pencapai target produksi crusher dengan melihat hasil kapasitas produksi teori dan nyata crusher dan untuk menentukan faktor-faktor yang mempengaruhi pencapaian target produksi dan kapasitas produksi aktua crusher.Hasil analisis kapasitas produksi aktual PT Banua Tapin Mandiri pada bulan November – Desember rata-rata sebesar 40.327 ton/bulan atau 1.845,05 ton/hari atau 267,99 ton/jam. Dengan merekomendasikan tiga sistem pengumpanan maka produktivitas unit crusher meningkat dari 183,5 ton/jam menjadi 527,31 ton/jam, Faktor-faktor yang mempengaruhi tidak tercapainya kapasitas produksi aktual tahun 2016 yaitu supply material batubara dalam setiap bulannya bervariasi antara 47.000-70.000 Kata-kata kunci : produksi teoritis crusher, produksi aktual, crushing plant

Application of Optimization Method for Calibration and Maintenance of Power-Based Belt Scale

Process optimization and improvement strategies applied in a crushing plant are coupled with the measurement of such improvements, and one of the indicators for improvements is the mass flow at different parts of the circuit. The estimation of the mass flow using conveyor belt power consumption allows for a cost-effective solution. The principle behind the estimation is that the power draw from a conveyor belt is dependent on the load on the conveyor, conveyor speed, geometrical design, and overall efficiency of the conveyor. Calibration of the power-based belt scale is carried out periodically to ensure the accuracy of the measurement. In practical implementation, certain conveyors are not directly accessible for calibration to the physical measurement as these conveyors have limited access or it is too costly to interrupt the ongoing production process. For addressing this limitation, a better strategy is needed to calibrate the efficiency of the power-based belt scale and maintain the reliability of such a system. This paper presents the application of an optimization method for a data collection system to calibrate and maintain accurate mass flow estimation. This includes calibration of variables such as the efficiency of the power-based belt scale. The optimization method uses an error minimization optimization formulation together with the mass balancing of the crushing plant to determine the efficiency of accessible and non-accessible conveyors. Furthermore, a correlation matrix is developed to monitor and detect deviations in the estimation for the mass flow. The methods are applied and discussed for operational data from a full-scale crushing plant.

Kinerja Unit Crushing Plant dalam Pengolahan Batuan Andesit Di Pt Bukit Asam, Tbk. Tanjung Enim, Sumatera

Meningkatnya pembangunan di kota Palembang beberapa tahun belakangan, membuat kebutuhan material konstruksi juga meningkat. Adanya andesit di daerah Tanjung Enim, seharusnya bisa menjadi pemasok batu split untuk daerah Palembang. Agar beton yang dihasilkan memiliki kualitas baik, ukuran batu split harus mengacu pada standar industri Indonesia. Untuk memenuhi standar tersebut, batu andesit hasil penambangan perlu diolah dan mengalami proses reduksi ukuran kemudian dianalisis agar memenuhi standar. Ukuran produk hasil pengolahan berkorelasi dengan kinerja unit crushing plant. Penelitian ini bertujuan untuk mengetahui pengolahan batu andesit serta menganalisis produktivitas crushing plant dan menganalisis kualitas hasil pengolahan. Penelitian dilakukan dengan mengamati kinerja unit crushing plant serta dilakukan analisis uji ayakan untuk mendapatkan nilai modulus kehalusan. Kemudian membandingkan nilai modulus kehalusan yang diperoleh dengan standar indonesia yang berkisar antara 6-7,10. Dari hasil penelitian diketahui produktivitas aktual unit crushing plant sebesar 142,1685 ton/jam dengan nilai ketersediaan alat kurang dari 64%. Berdasarkan uji analisis ayakan, didapatkan nilai modulus kehalusan sebesar 7,66 dan belum memenuhi standar industri Indonesia. Hasil dari pemecahan sangat beragam sehingga pada pengolahan batu andesit diperlukan unit secondary crusher.

STUDI WATER MANAGEMENT PADA AREA PLANT PRODUKSI DI PT SEBUKU IRON LATERITIC ORES (SILO) SITE SUNGAI BALI, KECAMATAN SEBUKU, KABUPATEN KOTABARU, PROVINSI KALIMANTAN SELATAN

PT Sebuku Iron Lateritic Ores memiliki 3 plant produksi untuk proses pengolahan dan pencucian bijih besi yaitu washing plant, crushing plant dan magnetic separator. Proses pengolahan tersebut menggunakan system open cicruit dan media air sebagai pencucian bijih besi, sumber air untuk kebutuhan proses produksi mengunakan air laut, air tampungan hujan dan air sirkulasi hasil dari proses pencucian bijih besi, air tersebut ditampung pada kolam endapan yang ada pada masing-masing plant dengan maksud mengurangi endapan lumpur sisa dari proses pencucian dan mengembalikan air dari proses tersebut untuk digunakan kembali. Tujuan dari penelitian ini adalah menghitung persen endapan lumpur pada tiap kolam, menghitung debit air yang masuk dan keluar dari tiap kolam, menganalisa hambatan-hambatan yang terjadi, membuat simulasi pembagian kebutuhan air untuk kegiatan produksi, dan penjadwalan pengerukan kolam endapan untuk mencapai kebutuhan air sirkulasi secara maksimal.Perhitungan persen endapan lumpur pada kolam didapatkan dari hasil bottle rolling test, perhitungan pembagian kebutuhan air tambahan dari debit pompa kolam dan perhitungan debit limpasan sesuai curah hujan. Perhitungan jadwal pengerukkan kolam endapan didapatkan dari dimensi kolam dan kecepatan aliran kolam.Air yang masuk pada system open circuit sebesar 860,01 m³/jam dan air yang kembali tersirkulasi sebesar 310,49 m³/jam atau 43,9%. Jumlah endapan yang masuk ke kolam endapan WP sebesar 35% asumsi sampel 1 liter dari debit yang masuk dan 29,33% masuk ke kolam endapan MS. Kebutuhan air tambahan untuk kegiatan produksi dibutuhkan sebesar 396,64 m³/jam atau 56,1%. Jadwal pengerukkan kolam WP 2-3 hari sekali dan MS 1-15 hari sekali. Dengan simulasi rekomendasi kolam endapan baru agar air sirkulasi yang didapat maksimal maka target pengendapan menjadi 99% dan air sirkulasi dari pencucian meningkat menjadi 82% dan hanya membutuhkan air tambahan sebesar 18%. Jadwal pengendapan untuk kolam rekomendasi WP dan MS dapat dilakukan 3 hari sekali. Kata-kata kunci: plant produksi, kolam pengendapan, system open circuit