1. Quarry Manager Development Program
Haulage & Transportation

2. Outline Objectives Rock Transportation Methods
Conveyor belts
Gravity
Haulers
Type of Haulers
Selection Criteria's
Characteristics and Specifications
Hauler Performance
Hauler Production Estimation
Haul Road Design Criteria's
Safety
Mining Op Hauling & transportation

3. Objectives Objectives:
Rock transportation requires a significant amount of energy and big size equipment.
This operation is dangerous. We have to understand how we can conduct this operation in a safe manner.
It is possible to optimize this process and to reduce the operating costs.
Mining Op Hauling & transportation

4. Rock Transportation Methods
The Main Rock Transportation Methods
Conveyor belts
A loading machine is feeding a crusher.
A mobile or semi-mobile crusher is following the quarry face.
The crusher feeds the conveyor belt.
Gravity
Glory holes, feeders of transfer points onto a conveyor belt, tunnels, crusher(s).
Rock slides
Haulers
Mostly trucks but also in some applications dozer(s), wheel loader(s), scraper(s), train wagon(s).
Mining Op Hauling & transportation

5. Rock Transportation Methods
The Rock Transportation Selection Criteria's are:
Safety
Environment
Flexibility and versatility
Availability
Effectiveness
Maintenance
Production cost
Mining Op Hauling & transportation

6. Outline Objectives Rock Transportation Methods Conveyor belts
Mining Op Hauling & transportation

7. Rock Transportation Methods – Conveyor Belts
Conveyor haulage
Usage of a mobile or semi-mobile crusher.
Extending or adding conveyor belt to the crushing unit.
Feeding the crusher with a back-hoe excavator.
Mining Op Hauling & transportation

8. Rock Transportation Methods – Conveyor Belts
Long belt conveying to plant.
Martres Quarry Conveying 0-300mm limestone to the plant
Mining Op Hauling & transportation

9. Rock Transportation Methods – Conveyor Belts
Conveyor Belts Classification (1)
In pit conveyor: to replace haulers / trucks: with portable /mobile crusher and steep- slope belt.
Overland conveyor: adapted to the terrain, they are:
Very strong for long distances,
Wide (900 to 1200 mm)
Fast (3-6 mt/sec)
High capacity (800 to 3000 tph)
In-Plant conveyor: most commonly used inside the plants, velocities from 1 to 3 m/sec.
Mining Op Hauling & transportation

10. Rock Transportation Methods – Conveyor Belts
Conveyor Belts Classification (2)
COSTS
Acquisition Cost is very high (1200 to 7000 USD/metre)
Operating Cost is low:
Labour Cost: very variable but low
Power Cost: very variable and low (upwards: conveyor consumes; downhill: it generates energy)
Annual Maintenance: 1 – 2 % of installed conveyor price.
When reasonable, replacing stationary crusher by a Mobile crusher + Conveyors to reduce mobile fleet must be assessed
Mining Op Hauling & transportation

11. Rock Transportation Methods – Conveyor Belts
Designing: Belt Width vs. Lump Size
Mining Op Hauling & transportation

12. Outline Objectives Rock Transportation Methods Conveyor belts Gravity
Mining Op Hauling & transportation

13. Rock Transportation Methods - Gravity
Mining in Steep & Vertical Slope: Du Jiang Yan Lafarge Limestone Quarry in China
Rock slide typically generate dust and an adverse visual impact
High dipping
Rock slide requires a safe unloading facility
Mining Op Hauling & transportation

14. Rock Transportation Methods - Gravity
Mining in Steep & Vertical Slope: Du Jiang Yan Limestone Quarry
Rock slide
stoppage of rock slide during loading
Loading trucks is performed when the rock slide is not utilized and vice versa
Unloading area
Mining Op Hauling & transportation

15. Rock Transportation Methods - Gravity
Mining in Steep & Vertical Slope: Du Jiang Yan Limestone Quarry
Rock slide mining operation issues
Problem to operate the rock slide at the same time with crusher.
Cleaning of rock slide
Flying stone
Action done & to be done to Improve the mining operations
Modification of some parts of the rock slide
Cleaning the rockslide frequently
Proper design for the second rock slide. Modification of the angle to avoid the remaining of sticky materials
Mining Op Hauling & transportation

16. Rock Transportation Methods - Gravity
Mining in Steep & Vertical Slope: Lafarge Kanthan Limestone Quarry in Malaysia
First Situation – Rock slides
Mining Op Hauling & transportation

17. Rock Transportation Methods - Gravity
Mining in Steep & Vertical Slope: Lafarge Kanthan Limestone Quarry in Malaysia
Intermediate Situation (Haul Methodology) – High Grade Slope
Mining Op Hauling & transportation

18. Rock Transportation Methods - Gravity
Mining in Steep & Vertical Slope: Lafarge Kanthan Limestone Quarry in Malaysia
Final Development
Mining Op Hauling & transportation

19. Rock Transportation Methods - Gravity
Glory Hole in the Lafarge Exshaw plant in Canada
Mining Op Hauling & transportation

20. Rock Transportation Methods - Gravity
Glory Hole in the Lafarge Exshaw plant in Canada
Limestone is introduced in the system by dumping over a 16” grizzly.
The boulders > 16” are crushed in the adjacent jaw crusher.
The limestone falls in a glory hole and is carried towards the impact crusher via a conveyor belt
Grizzly Bars above the glory hole
Mining Op Hauling & transportation

21. Rock Transportation Methods - Gravity
Glory Holes and Tunnels in the Lafarge Tavernola Plant (Italy)
The Tavernola Ca’Bianca quarry is in a mountain.
It consist of crushing the shot rock to a 150mm size.
It is then introduced in a series of three glory holes and transfer points till a secondary crusher and final stock pile of 0-80mm.
Glory Hole
Mining Op Hauling & transportation

22. Rock Transportation Methods - Gravity
Glory Holes and Tunnels in the Lafarge Tavernola Plant (Italy)
Upper Tunnel Exit
Glory Hole Transfer Point
Glory Hole and Tunnel Project
Mining Op Hauling & transportation

23. Outline Objectives Rock Transportation Methods Conveyor belts Gravity
Haulers
Type of Haulers
Mining Op Hauling & transportation

24. Hauler – Type of Hauler The Quarry Hauler Types
Dozer (in a rip & push quarrying methodology)
Wheel loader (in a load & carry quarrying methodology)
Scraper (for soft limestone like marl or chalk)
Trucks (on-road, quarry rigid frame or articulated)
Wagon or Train wagon (rarely used in our operations)
Mining Op Hauling & transportation

25. Hauler – Type of Hauler
Dozer: Lafarge Harleyville Plant in USA. The dozer is ripping and pushing the marl to the semi-mobile lump breaker
Mining Op Hauling & transportation

26. Possible mismatch between on-road trucks and other quarry equipment
Hauler – Type of Hauler
On-Road Truck
Used when transportation onto public road is required between the quarry shot rock face and the crusher at the plant.
Reinforced rock boxes are offered for hauling shot rock, but typically do not last long. Re-lining the box is required.
These trucks are not designed for hauling large piece of rock and therefore not ideal for shot rock applications. If these trucks are to be used, it is necessary to shoot the rock as fine as possible.
Possible mismatch between on-road trucks and other quarry equipment
Mining Op Hauling & transportation

27. Hauler – Type of Hauler Articulated Truck
Appropriate for poor underfoot, wet conditions and steep grades. Can be offered all wheel drive.
Typically used for overburden removal, but there are also suitable shoot rock application models (lined rock boxes)
The service life is shorter than in quarry trucks (rigid frame) ( 15,000 compared to 26, 000 hours)
The truck load capacity range is from 25 to 40 tonnes
Mining Op Hauling & transportation

28. Hauler – Type of Hauler Rigid Frame Truck
High horsepower to weight ratio
Deep pits. Requires a well maintained smooth haul road surface.
Can be used with any type of material ( e.g., blocky, free flowing, etc. )
Used for dumping into hoppers or over bank or fill
Economic distance limited
Mining Op Hauling & transportation

29. Hauler – Type of Hauler Wheel Loader
Frequently used with the Load & Carry quarrying methodology
Consist of loading at the shot rock face and haul to the mobile crusher
The economical hauling distance shall not exceed 100 meters
It is necessary to select the proper tire brand for this application
Mining Op Hauling & transportation

30. Hauler – Type of Hauler Scrapers
Used when the limestone body is soft (marl, chalk)
A dozer is sometimes required to assist the scraper loading process by pushing it. This happens when wet conditions prevails or when the rock surface is slippery.
Scrapers are known to be and economical hauling device when it can be utilized.
Mining Op Hauling & transportation

31. Hauler – Type of Hauler Haulers Economical Distance of Transportation
Mining Op Hauling & transportation

32. Outline Objectives Rock Transportation Methods Conveyor belts Gravity
Haulers
Type of Haulers
Selection Criteria's
Mining Op Hauling & transportation

33. Hauler – Selection Criteria's
Criteria's to consider for the selection of haulers
Production requirement and operating schedule
Material characteristics
Density in place and loose, swell
Size distribution, Maximum and Minimum
Hardness and texture
Ease of handling
Number and type of trucks selected should be based on overall system economics
Select the fleet based on both operating and capital cost
Mining Op Hauling & transportation

34. Hauler – Selection Criteria's
Criteria's to consider for the selection of haulers
Physical and climatic conditions
Effect of altitude on engine efficiency
Effect of ambient temperature on engine cooling, tire performance, and use of lubricants
Effect of rainfall, frost, snow, fog, etc. on road conditions and transportation
Haul road characteristics
Length, grade, and surface condition of segments
Mining Op Hauling & transportation

35. Hauler – Selection Criteria's
Criteria's to consider for the selection of haulers
Loading
Space and ground conditions at loading point
Type and size of loading equipment
Total availability of loading equipment
Dumping
Dumping arrangements: rear dump into hopper, drive over hopper, edge of spoil, windrow, etc.
Space and ground condition at dump point
Total availability of down stream equipment
Mining Op Hauling & transportation

36. Outline Objectives Rock Transportation Methods Conveyor belts Gravity
Haulers
Type of Haulers
Selection Criteria's
Characteristics and Specifications
Mining Op Hauling & transportation

37. Hauler - Characteristics and Specifications
Hauler Dimensions vs. infrastructures and other equipment
Mining Op Hauling & transportation

38. Hauler - Characteristics and Specifications
Matching the Hauler Productivity with the Productivity of the Loading Unit
Mining Op Hauling & transportation

39. Outline Objectives Rock Transportation Methods Conveyor belts Gravity
Haulers
Type of Haulers
Selection Criteria's
Characteristics and Specifications
Hauler Performance
Mining Op Hauling & transportation

40. Hauler Performance The Factors Affecting the Hauler Performance
Rolling Resistance
Grade Resistance
Weight and Traction
Altitude Deration
Road Design
Tires
Fuel (Quality)
Maintenance
Operators and Mechanical skills
Mining Op Hauling & transportation

41. Hauler Performance– Rolling Resistance
Measure of the force required to overcome internal bearing friction and the retarding effect between the tires and the ground (i.e., tire penetration and tire flexing)
Expressed in terms of lb/ton vehicle weight or % vehicle weight
Mining Op Hauling & transportation

42. Hauler Performance– Grade Resistance
Force required to overcome gravity when moving vehicle uphill. Expressed in % vehicle weight (adds power to vehicle downhill)
Percent Grade =
Vertical rise or drop (ft) x 100
Horizontal Distance (ft)
e.g., 60 ft rise in 1,000 ft, Grade = 60/ 1,000 x 100 = 6%
Horizontal Distance = (Horizontal distance2 + vertical distance2)1/2
e.g., (1, )1/2 = 1,001.8 ft
Mining Op Hauling & transportation

43. Hauler Performance– Weights and Traction
Weights: determines the force required to propel vehicle
Function of vehicle weight, rated capacity (CY), and density of material hauled, number of passes of excavator
Traction: the force deliverable can be limited by traction conditions
Usable rimpull is a function of road surface and weight on the drive wheels
Usable Rimpull = Coefficient of Traction x Weight on Drive Wheels
Mining Op Hauling & transportation

44. Hauling Performance – Road Design
Speed Limits: limits on curves, in pit, and on main haul roads
Curves based on radius and super-elevation
In pit, ramp, and main haul roads, the speed limit depends on haul road width and conditions
Mining Op Hauling & transportation

45. Hauler Performance– Tires
Tire Impact
Can reduce the hauler productivity by limiting load and speed
Ton-mile-per-hour ratings should not be exceeded and depend on
Weight (Flex/revolution)
Speed (Flexes/period)
Ambient Temperature
Road Surface Temperature
Mining Op Hauling & transportation

46. Hauler Performance– Tires
Tire KPI’s
TMPH = Average Tire Load x Average Speed for Shift
Average Tire Load = Empty Truck Tire Load + Loaded Truck Tire Load (tons) 2
Average Speed = Round Trip (mi) x Trips/Shift
Total Hours (hr)
Tire type may include a maximum speed and a resulting lower productivity
Mining Op Hauling & transportation

47. Outline Objectives Rock Transportation Methods
Conveyor belts
Gravity
Haulers
Type of Haulers
Selection Criteria's
Characteristics and Specifications
Hauler Performance
Hauler Production Estimation
Mining Op Hauling & transportation

48. Hauler Productivity Estimation
Effect of acceleration, deceleration and operator skills
Speeds obtained from performance curves in handbooks indicate maximum velocity under optimum conditions on a given profile
These speeds must be corrected for acceleration, deceleration, and operator performance to yield reasonable haul and return times.
F=Ma Simulation utilized to account for acceleration and deceleration
Hauling cycle times simulations typically underestimate the real hauling cysle times
Mining Op Hauling & transportation

49. Hauler Productivity Estimation
Estimating Hauler Cycle Time
Hauler Loading Time: loading machine bucket size, fill factor, excavator cycle time, loose material density, and truck capacity (typically 2 min)
Other Fixed Times: depend on loading method and dump configuration
Spot and manoeuvre in loading area (typically min)
Dumping (typically 1.2 – 1.5 min)
Hauler Traveling Time (Loaded and Empty):
Truck payload
Effective work per hour
Operating efficiency
Grade and rolling resistance
Speed limit
Mining Op Hauling & transportation