Aftek's Mine Logistics Solution (MLS) is an integrated electronic hardware and software solution. It is designed to improve mining efficiency and productivity for open pit mines.
Deploying individual components of MLS in the mining area and on the equipment, facilitate collecting real-time data and sending to the control room through seamless RF mesh network. It enables the control room officials to constantly stay in touch with ground mining staff and the activities. Taking timely decisions in case of mechanical equipment failure or deploying additional resources wherever required would save production loss; and consequently increase the production and profitability.
Mining requires an integrated interaction among many resources like supervisors, dumper drivers, shovel operators, maintenance staff, planning department and mechanical equipments for ore extraction.
The key to profitability in the mining business is effectively monitoring and controlling these highly valuable resources at optimum cost. Getting real time information puts you directly in control of these mine equipments, evades production loss, and improves mine safety.
It is an indigenously designed and developed electronic hardware and parameterized software application based on GPS, Wi-Fi, RF and MS .Net technology. The application collects data in real-time from different equipments such as shovels, dumpers, water tankers, wheel loaders and supervisors inside the pit. Using the powerful Discrete Event Simulation algorithm, analyzes the data collected, verifies it against estimated production, and assists or automates hauling of the dumpers and shovels. The algorithm takes care of minimizing dumper queuing and shovel idling. By setting the shovel priority and directing more dumpers toward this shovel with minimal idling, the production can be increased.
The critical alerts received from various dumpers and shovels are used to take appropriate corrective action. Using the "Not Required" notification from shovel and dumper, the equipment can be moved to another work location for optimal usage or stopped completely to avoid wear and tear and fuel saving.
Shovel idle time can be constantly monitored to assign additional dumpers and increase the production. The simulation module facilitates estimating the production for a group of shovel and dumpers based on the material (ore, waste) excavation pattern. It also considers the distance of the dumping location for the calculation of the material weight. You can also make real time enquiries and give instructions to the mine staff and vehicle operators.
The solution also automates supervisors' task of "data entry" by sensing the dumper arrival in the vicinity of shovel. The trip information is automatically registered on the dumper and control room. The report-viewer application generates reports such as shovel production, dumper trips, material-production, shovel idling, machine shift (MSR) and total shift production.
The production console continuously displays the production status graphically. The control room authorities monitor it against the estimated production and take corrective action if required.
The map console application displays the current dumper and shovel locations on the GIS map. Other information including dumper trips, material filled, dumper speed, vehicle operator name, shovel idling time, dumpers served by shovel and total shovel production are also shown.
An optional feature for vehicle workshop moduleis provided to obtain alerts from mine vehicles, maintenance reminders, fuel consumption and refilling vigilance.
Also provided is an optional feature for power management that can automatically switch-on and switch-off the mine pole lamps and diesel generators at a predefined interval.
The following table depicts the production comparison between "auto dispatch" and "fixed dispatch". The fixed dispatch method typically assigns a fixed number of dumpers to a particular shovel for ore transportation. Aftek's auto dispatch algorithm allows dynamic dumper assignment to the shovels, based on the trip timings and material excavated; resulting in the best utilization of mine equipments.
|Parameters||Auto dispatch||Fixed dispatch||Difference||Percentage|
|Timeline||480 minutes (single shift)|
|Excavation pattern||60% Iron ore and 40% waste|
|Dumpers (35 tons)||12 (6 each for Fixed dispatch)|
In the above consideration, if the auto dispatch algorithm is exercised for a single shift with 2 shovels and 12 dumpers, there is a 2.7% increase in production.
Consider an average production of 25,000 tons per day, assume price per ton is $40 and assume the production cost $5 per ton. The total additional earnings per day would be $23,625 with a 2.7% increase in the production as shown in the above chart.