Kemerburgaz Çiftalan Köyü açık kömür ocaklarında dekapaj kazı ve nakliyat projesi
Kemerburgaz Çiftalan Village open coal mine excavation and hauling project
Yazar: İSMAİL CEM SOLMAZ
Danışman: DOÇ.DR. İSMAİL UĞUR
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü
Derece: Yüksek Lisans, 1995
Konu: Maden Mühendisliği ve Madencilik = Mining Engineering and Mining
Dizin: Açık ocak madenciliği = Open pit mining ; Dekapaj = Pickling ; Kömür ocakları = Coal mines ; İstanbul-Kemerburgaz-Çiftalan köyü = İstanbul-Kemerburgaz-Çiftalan village

Özet:
This study aims at scrupulous comparison af trans- portatin of stripping contained'at the öpen coal mine ouned by Kutman Mining Co. Ibcated in the vicinity of Kemerburgaz Çiftalan Village either hauling by truck ar by conveyor belt system. As a consequence of such comps? rising dramp truck haulage uıas selected as conveyance system and application made to representatives of importess marketing trucks and excavators for direct discussions, subsequently, pruchasable trucks and excavators uere deter- mined and concordant functioning dual systems uere formed in terms of capacity and requireıd.'loading height to be put into operation uith the said trucks and excavators. Costs of each system uas determined and the most suitable and economlcal system mas selected. 1.Transportation by Canveyor Belt System The system nau-a-days productively used at Çiftalan Uillage duarries, is conveyance of stripping to dumping locations via trucks after completion of stripping by bucket excavators. The other option, i.e., Conveyor Belt System has proven to be problematic on grounds that strip¬ ping dumping locations subject to constant alterations. Conveyor.Belt System is not a temporary ör periodical conveyance system such as truck haulage but oughfto be in application. Due to such system being a perrianently operated'means of conveyance, in order to procure high yield morking capacity at the place of uork, the material subject conveyance should be excavate 'by a permanently operated system. Considering applieation of excavation proc.edure by a bucket axcavator ör a similar equipment, ue come to an enuquivocal conclusion that hydraulic- bucket excavator and conveyor belt system do not fit to operate synchronously. Stripping procedure effected.'by hydraulic-bucket excavator does not have sufficient capa¬ city to fSed the conveyor belt system. it seems that, the most productive excavation equipment applicabel to

Abstract:
This study aims at scrupulous comparison af trans- portatin of stripping contained'at the öpen coal mine ouned by Kutman Mining Co. Ibcated in the vicinity of Kemerburgaz Çiftalan Village either hauling by truck ar by conveyor belt system. As a consequence of such comps? rising dramp truck haulage uıas selected as conveyance system and application made to representatives of importess marketing trucks and excavators for direct discussions, subsequently, pruchasable trucks and excavators uere deter- mined and concordant functioning dual systems uere formed in terms of capacity and requireıd.'loading height to be put into operation uith the said trucks and excavators. Costs of each system uas determined and the most suitable and economlcal system mas selected. 1.Transportation by Canveyor Belt System The system nau-a-days productively used at Çiftalan Uillage duarries, is conveyance of stripping to dumping locations via trucks after completion of stripping by bucket excavators. The other option, i.e., Conveyor Belt System has proven to be problematic on grounds that strip¬ ping dumping locations subject to constant alterations. Conveyor.Belt System is not a temporary ör periodical conveyance system such as truck haulage but oughfto be in application. Due to such system being a perrianently operated'means of conveyance, in order to procure high yield morking capacity at the place of uork, the material subject conveyance should be excavate 'by a permanently operated system. Considering applieation of excavation proc.edure by a bucket axcavator ör a similar equipment, ue come to an enuquivocal conclusion that hydraulic- bucket excavator and conveyor belt system do not fit to operate synchronously. Stripping procedure effected.'by hydraulic-bucket excavator does not have sufficient capa¬ city to fSed the conveyor belt system. it seems that, the most productive excavation equipment applicabel tooperate in conjunction uith conveyor belt system would be permanently operating rotating-bucket excavator. Upon inquiries conducted.., through belt-conveyor manufacturing firms we have come to know that a substantial portion of belt conveyance systems are currently manufactured in Turkey, nevertheless, excavation equipment to feed the belts in large quantities are totally dependabed to importation from abroad, such is the case in truck trans portation, kle relinquished cost calculation procedure of 'the conveyor belt system on grounds of the dilemma encountered as to production areas and stripping dumping locations are altered just too often. 2. Dump Truck Transportation Stripping is conveyed from open coal mine of the region to dumping area by excavator truck system. The underlying reason for preferring truck system for conve yance is alteration of production and dumping areas in very short respite and its easy adaptation to differing conditions and requirements of transportation. Such unique characteristics of the area unequivocally attracted even greater application of truck transportation system. The tipper-body capacity of dump truck applicable in conjunction with bucket excavators ought to be k to 5 times larger than the bucket capacity. In addition, the truck should be loaded with full number of buckets. To enable the excavator operate in full yield it should not beforced to stall to wait for transportation vehicle. Hence, sufficient number of trucks ought to be assigned for the excavator. Calculation of the number of vehicles allocated for the purpose would naturally be subject to many factors, such as the average speed of the truck, the period of loading, time elapsed'for the excavator to load, moving and dumping of the same, volume of the bucket, bucket filling factor, time elapsed whilst maneuvering of the vehicle at the port of loading/unloading, productivity of the working site, etc. Unless an unison is provided fur bucket/truck system between work load, truck's tonnage, unit number of trucks employed, and bucket filling factor, to attain the desised rate"- of productivity would be impossible for the existing loading gear and transportation vehicles. There are great number of firms being engaged in trade of earth moving equipment in our country. Table 1. illustrates the names list of the supplier firms and brand names of earth moving equipment supplied'to the markets. xiTABLE: 1. The Maries List of the Supplier Firms and Brand Names of Earth Moving Equipment Name of the Supplier ÇUKUROVA TEMSA ENKA BDRUSAN TRAKMAK DEKAŞ GÜRİŞ DAEWOO Brand Name of Earth Moving Equipment LIEBHERR KOMATSU HITACHI CATERPILLAR VOLVO AKERMAN COBELCO COBELCO,CASE,FURUKAWA DAEWOO LTD., KOREA Among the earth moving equipment offered are tire and palette excavators, uhell loaders, palette loaders, graders/scrapers, bulldozers, road-rollers, off-road trucks, fork-lifters, etc. Within a period of 11 calendar months a total of 4.35B.817m3 excavation works mas realized uiithin the licensed open coal mine of Kutman Mining Co. located in the vicinity of Kemerburgaz Çiftalan Village. Monthly work period is 26 calendar days and daily amount of work is 1 0 hours. Excavation quantity per hour mas calculated as 1524m3 as based upon the below indicated formulae. Daily amount of stripping (m3/day)= Annual amount of stripping (m3/ \ ^ a year) Annual amount of days actually worked (Day) Hourly amount of stripping (m3/hours) Daily amount of stripping (m3 A Daily hours of work actually served (Hour) The hourly production of a excavator was calculated as follows: n 3600 _ 0. = qx p x E m Q_: HDurlyproduction (m3/hr) q: Production per cycle (m3) q=q>, x Kq1 : Bucket capacity (m3) K : Bucket factor (O.B) Earth volume conversion factor : 1.8 t/m3 C : Cycle time (sec) E : 3ob efficiency (0.75) Number of bucket = La*d **?***?*)/ °f dump truck(fn) Production per cycle (ton) After these calculations, suitable excavators and dump trucks were determined. LJhen carrying out operations using a suitable number of dump trucks of suitable capa city to match the excavator, the operating efficiency was calculated in the following order. - Time required for loader to fill dump truck. - Hauling time - Time required for unloading plus time expended for standby until unloading is started. - Time required for returning. - Time required for dump truck to be positionned " f or loading and for the loader to start loading. The cycle time was calculated as follows; C,= n.C + n h t. + - n + t" " mt ms U1 1 V.. 11 C.: Cycle Time (sec) n : Number of cycles required for loader to fill dump truck C : Cycle time of loader(sec) D : Hauling distance of dump truck (m) \L : Average speed of dump truck (m/sec) M*. : Average speed for empty truck (m/sec) t. : Time required for dumping + time required for stand by until dumping is started (sec) t.* : Time required for truck to be positioned "and for loader to start looading (sec) The quantity of dump truck = Cycle Time of " dump truck(sec) Loading Time (sec)Number of needed excavators and truck were determined by following formulae. Number of excavator = Production (m3) Capacity of excavator (m3) Total number of dump truck = Number of dump truck x Number df excavator Number of needed excavators and dump trucks are shown table 2. T.ABLE:2. Excavator and Truck Number in the Truck and Excavator Dual System 3- Owning and Operating Cost When the trucks and excavators number were held tht production cost of avery machine in the system, the deprivation cost, fuel consumption cost, lubricants consumption cost, repairing cost, worker's wage cost tire consumption cost were calculated.The cost of system, shows that 1524 m3/hour produc tion uith the cost of both truck and excavator. The stated numbers in the truck and excavator dual system, are the number which is equal to optimum truck and excava tor number, 1524 m3/hour. In the 8 unit excavator and truck dual systems, before deciding which is the best the decrease in the production in hour, due to the extra ordinary situation, the effects of this decrease to the coats were also calculated.' The production units in the first setting were decrease to the 1398 m3/hour, in the second 10DD m3/hour and third to the 600 m3/hour, so that truck and excator number and cost were calculated and were showed tables. In the PC10DD/HD325-6 excavator-truck systeji) whick is seilected from 8 unit truck excavator systems, totaly 4 unit excavator and'24 unit. truck were pianpedi to use. The owning cost of the system is 364.200.000.000 TL. The operating cost of system is 1 40.1 43.8B0.000 TL. The production cost of system consist of 42 % depreciation cost, fuel consumption cost 24 %, lubricants consumption cost 2 %, tire consumption cost 2%, repairing cost 19 %, wage's cost 1%, insurance cost 10 %. XV