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Executive Summary
This report provides an analysis and evaluation of a fleet of trucks and loaders to meet the production requirements of an open pit mine. The method of analysis was first to determine the cycle time for each truck which led to calculating the amount of each dump truck necessary to meet the waste removal requirement of 70 Mt/pa. Secondly, an expected cost for ten years was conducted on each Komatsu dump truck and cross analysed to determine the most cost efficient option. It was found that the Komatsu 930E-4 had the least expected cost over the ten years. Then cross analysing, each loader with the Komatsu 930E-4 truck, it was determined that the Hitachi EX8000-6 was the most efficient loader for a fleet of Komatsu 930E-4 trucks. Once these were completed, a full haul truck cycle time and expected cost analysis for each year was calculated. It revealed that thirty four Komatsu 930E-4 dump trucks were needed for a single Hitachi EX8000-6 loader. However, the above analysis was limited by the fact that it didn’t account for truck and loader break downs. By taking into account a 10% threshold on the number of trucks and loaders needed it gave some costs accounting for time where not all trucks are operational. This analysis yielded that a fleet of thirty seven Komatsu 930E-4 dump trucks and two Hitachi EX8000-6 loaders would be best suited for the Kangaroo Mining Corporation. The expected costs for both loaders and dump trucks were calculated (refer to table 1.9) and showed that the average expected cost per year of hauling and loading would be $142 613 457/pa and $11 869 288/pa respectively. Furthermore, the average expected cost per tonne of hauling and loading would be $2.04/t and $0.17/t respectively.

Table of Contents

Executive Summary 2 Introduction 4 Parameters 4 Assumptions and Calculations 7 Analysis 10 Conclusion 11 Appendix 12 References 22

Introduction
This short report will discuss the best fleet choice for loaders and haul trucks to meet the waste removal target for an open pit mine of Kangaroo Mining Corporation. Furthermore, it will provide an insight to the cost of loading and hauling waste per year as well as the cost per tonne. It will demonstrate an analysis of expected costs per year for the ten year life cycle of the project and how the sensitivity of fuel cost will affect the overall expected costs if it changes.

Parameters
The Kangaroo Mining Corporation provided the following data: Data Received | Operator Salary (plus 9.5% Super) | $100 000 | $9 500 (Super) | Working roster | 14 days on, 7 days off | Rate of Waste | 70 Mt/pa | Powder Factor | 0.6 kg/m3 | Explosive cost | $1 000/t | Swell Factor | 25% | Road Gradient | 10% | Road Maintenance | Haul road will be well maintained, and watered daily to reduce dust | Waste Rock | Granite (UCS 100 MPa) | Fuel Cost (± 10%) | $1.40/L | $1.26/L | $1.54/L | Loader Lubrication cost | 10% of Maintenance cost for loaders | Truck Lubrication cost | 7.5% of Maintenance cost for trucks |

Figure 1: Planned open pit design for Kangaroo Mining Corporation
Figure 1: Planned open pit design for Kangaroo Mining Corporation

The following Hitachi loader specifications are parameters in calculations and can be justified by referring to table 1.1 (Hitachi Construction Machinery 2004). Hitachi Loaders | Model | Purchase Cost ($) | Maintenance Parts And Labour ($/hr) | Travel Speed (km/hr) | Fuel Capacity (L) | Engine Power (kW) | EX1200-5D | 1000000 | 120 | 3 | 1400 | 567 | EX1200-6 | 1000000 | 120 | 3 | 1470 | 567 | EX1900-6 | 2000000 | 150 | 2.5 | 4140 | 810 | EX2500-6 | 4000000 | 180 | 2 | 5000 | 1044 | EX2600-6 | 5000000 | 190 | 2 | 5300 | 1119 | EX3600-6 | 7000000 | 210 | 2 | 7450 | 1450 | EX5500-6 | 9000000 | 230 | 2 | 11300 | 2088 | EX5600-6 | 9000000 | 230 | 2 | 11300 | 2238 | EX8000-6 | 11000000 | 280 | 2 | 14900 | 2900 |

Hitachi Loaders | Model | Loading Capacity (m3) | Loading Capacity (tonnes) | EX1200-5D | 6.5 | 11.7 | EX1200-6 | 6.5 | 11.7 | EX1900-6 | 12 | 21.6 | EX2500-6 | 15 | 27 | EX2600-6 | 15 | 27 | EX3600-6 | 21 | 37.8 | EX5500-6 | 27 | 43.3 | EX5600-6 | 29 | 46.4 | EX8000-6 | 40 | 64 |

The following Kotmatsu trucks specifications are parameters in calculations and can be justified by referring to table 1.2 (Komatsu Australia n.d). Komatsu Trucks | Model | Purchase Cost ($) | Maintenance Parts and Labour ($/hr) | Travel Speed (km/h) | Fuel Capacity (L) | HD325-7 | 1000000 | 80 | 70 | 484 | HD405-7 | 2000000 | 90 | 70 | 780 | HD465-7E0 | 3000000 | 100 | 70 | 780 | HD785-7 | 3500000 | 100 | 65 | 1308 | HD1500-7 | 4000000 | 130 | 58 | 2120 | 730E 7 | 4500000 | 140 | 55.7 | 3217 | 730E 8 | 4500000 | 170 | 64.5 | 3217 | 830E 1AC | 5000000 | 190 | 64 | 4542 | 860E 1K | 5500000 | 210 | 64.5 | 4542 | 930E 4 | 6000000 | 220 | 64.5 | 4242 | 930E 4SE | 6500000 | 240 | 64.5 | 5300 | 960E 1 | 7000000 | 260 | 64.5 | 5300 | 960 2K | 7000000 | 260 | 64.5 | 5300 |

Komatsu Trucks | Model | Loading Capacity (m3) | Carrying Capacity (tonnes) | Tyres | Tyre Cost ($) | Engine Power (kW) | HD325-7 | 24 | 36.5 | 18.00 R33 | 2000 | 371 | HD405-7 | 40 | 63 | 24.00 R35 | 3500 | 371 | HD465-7E0 | 34.2 | 55 | 24.00 R35 | 3500 | 533 | HD785-7 | 60 | 91 | 27.00 R49 | 4500 | 879 | HD1500-7 | 78 | 144.1 | 33.00 R51 | 17250 | 1109 | 730E 7 | 111 | 183.73 | 37.00 R57 | 20000 | 1491 | 730E 8 | 111 | 181.4 | 37.00 R57 | 20000 | 1492 | 830E 1AC | 147 | 221.6 | 40.00 R57 | 22500 | 1865 | 860E 1K | 221 | 253.3 | 50/80 R57 | 35000 | 2014 | 930E 4 | 211 | 291.8 | 53/80 R63 | 50000 | 2014 | 930E 4SE | 211 | 290.4 | 53/80 R63 | 50000 | 2611 | 960E 1 | 214 | 326.58 | 56/80 R63 | 50000 | 2610 | 960 2K | 214 | 326.58 | 56/80 R63 | 50000 | 2610 |

Assumptions and Calculations
To determine the best choice of haul trucks and loaders the calculations were split up into determining which haul truck would be best to use and the loader to best suit the selected haul truck. Before starting the costs analysis and calculations certain assumptions were made. The first assumptions that were made were: * The open pit mine is operational 365 days a year, 12 hours a day. * The explosive cost per year is the same for each truck and loader.

Given that the waste rock is granite with a UCS of 100 MPa the density of the rock can be found to be 2700 kg/m3 (Afrouz 1992). It is possible to calculate the density of the blasted rock:

Density of blasted waste rock= Density of rockswell factor
Density of blasted waste rock= 27001.25
Density of blasted waste rock= 2160 kg/m3

Furthermore from the parameters the calculation of the explosive cost per year is the following:
Explosive cost per year=Exposive cost per tonne ∙Rate of wasteDensity of rock ∙Powder factor
Explosive cost per year=1000 ∙70 000 0002700 ∙0.6
Explosive cost per year=$15 555 555.55/pa
However, as this explosive cost per year is constant throughout all trucks, it does not need to be considered in the calculations of the open pit mine.

The haul truck that has the lowest expected cost was determined by assuming that that each truck had a loader that takes 4 buckets to load each truck with the exact same amount of time. The time taken for the loader to load the first bucket was assumed to be 20 seconds and each one after 30 second. Furthermore, the availability, utilisation of availability and operator efficiency are assumed to be 85%, 88% and 87% respectively (Durham 2014). For a haul truck cycle time to be completed the rolling resistance, speeds reach, unload time and time taken for truck to get into position to be loaded must be known. From Durham (2014) the rolling resistance for a well maintained haul road has a value of 3% for the ramp and 5% for pit floor and surface. An assumption for the open pit mine was that speed limits of 20 km/hr on the pit floor and 40 km/hr elsewhere were enforced. Given that the maximum speeds for all the trucks are similar it led to the assumption that on flat ground (pit floor and surface) the maximum speed limit of 40 km/hr was reached. Additionally, the speeds reached by the haul trucks were assumed to be a maximum going down the open pit ramp and only 30 km/hr going up the ramp with a gradient of 10%. Additionally, the assumption for the unload time and position time are 40 seconds and 30 seconds respectively (Durham 2014). After the above assumptions were made, a haul truck cycle time (see table 1.5) was employed for each truck to see how many trucks would be needed each year as the depth increased to meet the goal of 70 Mt/pa of waste removal. Then using the number of trucks, fuel cost, maintenance cost, tyre cost, employee cost and lubrication cost it is possible to determine the expected cost. An analysis was conducted between all the haul trucks expected costs over the 10 year life cycle. It demonstrated that the cheapest haul truck over 10 years would be Komatsu 930E-4 (see table 1.3 and 1.4).

The following equations were used to calculate the expected cost.
Expected cost=Number of trucks∙cost of truck+Maintenance cost+Fuel cost+Tyre Cost+Employee Cost+Lubrication Cost

The number of trucks was determined by a haul truck cycle time analysis which was stated earlier (Refer to table 1.5 in appendix for number of trucks of Komatsu 930E-4).

Calculating maintenance cost
Maintenance cost=Number of opertional hours ∙Maintenance cost per hour

Calculating fuel cost
Fuel cost=Fuel consumption per hour ∙Number of operational hours∙Fuel cost per litre

Calculating fuel consumption per hour
Fuel consumption per hour=Z ∙Engine Power
Where Z is assumed to be 0.19 (Karrech 2014).

An assumption was made when calculating tyre cost that 4 sets of tires are used per year and each truck needs 6 tyres to function.
Calculating tyre cost
Tyre cost=Number of tyres used∙cost per type

Calculating employee cost
Employee Cost=Number of employees ∙(Salary Per Year+Super)

Calculating number of employees
Number of employees= Number of trucks ∙Number of employeees needed per truck

Calculating number of employees per truck is determined by the work roster. In this case the work roster is 14 days on, 7 days off. Analysing this yields that 3 employees are needed for every two trucks or loaders.

Calculating lubrication cost for trucks
Lubrication cost=0.1∙Maintenance cost of trucks

Calculating lubrication cost for loaders
Lubrication cost=0.075∙Maintenance cost of loaders

In the case of choosing the best loader for the Komatsu 930E-4 a cross analysis of loader bucket capacity and truck capacity was conducted. It demonstrated that the Hitachi EX8000-6 loader is best suited for a fleet of Komatsu 930E-4 dump trucks (refer to table 1.6). It shows that the original assumption that the loader will only take four buckets to load the haul truck was incorrect. Instead the Hitachi EX8000-6 will take five buckets to full load the Komatsu 930E-4. Thus illustrating that the calculations for the number of trucks needed to meet the rate of waste removal requirement was incorrect. Recalculating the haul truck cycle time with five loading buckets and only one Hitachi EX8000-6 yields that at the end of the ten years, 34 Komatsu 930E-4 haul trucks are needed (see table 1.7).

Analysis
Analysing Table 1.8 in appendix of the calculated data for expected costs demonstrates that the majority of the costs, over the ten years, are in the last few years where a large number of haul trucks are needed to meet the production requirement. However, this calculation does not account for times when the trucks or loader are not operational. To account for this limitation it is suggested that a 10% threshold be used for the number of Hitachi EX8000-6 and Komatsu 930E-4. Accounting for this in the calculations yields that the average expected cost; for loading per year is $11 869 288/pa, for loading per tonne is $0.17/t, for hauling per year $142 613 457/pa, for hauling per tonne is $2.04/t. Table 1.9 illustrates the expected costs for each year considering the 10% threshold. The trend of the expected cost shows that as the pit depth increases the expected cost per year increases over the ten year period which can be emphasized in figures 2 and 3. Furthermore, it is apparent that as the price of fuel changes it causes a change in the expected cost. The effect of fuel price varying with a ± 10% of the original fuel cost assumption on the expected cost per year is shown in figures 2 and 3. It is evident from these figures that the sensitivity of fuel cost has a significant effect as the number of dump trucks increases which increases as pit depth increases.ow

Conclusion
To conclude, the most cost efficient and cost effective removal of waste rock is a fleet of thirty seven Komatsu 930E-4 dump trucks and two Hitachi EX8000-6 loaders. It indicated through the analysis that the average expected cost per year of hauling and loading would be $142 613 457/pa and $11 869 288/pa respectively. Additionally, the averaged expected cost per tonne of hauling and loading would be $2.04/t and $0.17/t respectively. The analysis revealed that the costs per year and tonne increases as the depth of the open pit mine increases. However, as with any model analysis it is limited by the assumptions made. If the assumptions are wrong or can change in any way it will affect the final results of which fleet of vehicles are needed to achieve the most cost efficient and effect to meet the removal requirements.

Appendix
Table 1.1: All specifications for Hitachi loaders can be found on these pages Hitachi Loaders | Model | | EX1200-5D | http://www.hitachi-c-m.com/au/products/excavator/large/ex1200-5d/ | EX1200-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex1200-6/ | EX1900-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex1900-6/ | EX2500-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex2500-6/ | EX2600-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex2600-6/ | EX3600-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex3600-6/ | EX5500-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex5500-6/ | EX5600-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex5600-6/ | EX8000-6 | http://www.hitachi-c-m.com/au/products/excavator/large/ex8000-6/ |

Table 1.2: All specifications for Komatsu Dump trucks can be found on these pages

Komatsu Trucks | Model | | HD325-7 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/HD325-7.aspx | HD405-7 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/HD-405-7.aspx | HD465-7E0 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/HD465-7EO.aspx | HD785-7 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/HD785-7.aspx | HD1500-7 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/HD1500-7.aspx | 730E 7 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/730E-7.aspx | 730E 8 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/730E-8.aspx | 830E 1AC | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/830E-1AC.aspx | 860E 1K | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/860E-1K.aspx | 930E 4 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/930E-4.aspx | 930E 4SE | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/930E-4SE.aspx | 960E 1 | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/960E-1.aspx | 960 2K | http://www.komatsu.com.au/Equipment/Pages/Dump%20Trucks%20-%20Rigid/960E-2K.aspx |

Table 1.3: Expected cost analysis for each dump truck TRUCKS | Cost of Fleet ($) | Maintenance Cost ($) | Fuel Cost ($) | Fuel Cost -10% ($) | Fuel Cost +10% ($) | HD325-7 | 206000000 | 611798400 | 754699211.3 | 679229290.2 | 830169132.4 | HD405-7 | 240000000 | 399718800 | 438296105.5 | 394466495 | 482125716.1 | HD465-7E0 | 411000000 | 508518000 | 720966650 | 648869985 | 793063315 | HD785-7 | 290500000 | 307476000 | 718921934.6 | 647029741.2 | 790814128.1 | HD1500-7 | 212000000 | 255660600 | 580141100.3 | 522126990.3 | 638155210.3 | 730E 7 | 184500000 | 215233200 | 609734132.3 | 548760719.1 | 670707545.5 | 730E 8 | 189000000 | 265077600 | 618834572.2 | 556951114.9 | 680718029.4 | 830E 1AC | 170000000 | 242170200 | 632306392.2 | 569075753 | 695537031.4 | 860E 1K | 165000000 | 235468800 | 600696606.7 | 540626946 | 660766267.4 | 930E 4 | 156000000 | 214882800 | 523263059.8 | 470936753.8 | 575589365.7 | 930E 4SE | 169000000 | 234417600 | 678371325.2 | 610534192.7 | 746208457.8 | 960E 1 | 161000000 | 226621200 | 605130901.2 | 544617811.1 | 665643991.3 | 960 2K | 161000000 | 226621200 | 605130901.2 | 544617811.1 | 665643991.3 |

Table 1.4: Expected cost analysis for each dump truck TRUCKS | Tyre Cost ($) | Employee Costs ($) | Lubrication Cost ($) | TOTAL ($) | TOTAL -10% fuel ($) | TOTAL +10% fuel ($) | HD325-7 | 83808000 | 286780500 | 45884880 | 1988970991 | 1913501070 | 2064440912 | HD405-7 | 85176000 | 166549500 | 29978910 | 1359719316 | 1315889705 | 1403548926 | HD465-7E0 | 97524000 | 190694250 | 38138850 | 1966841750 | 1894745085 | 2038938415 | HD785-7 | 75816000 | 115303500 | 23060700 | 1531078135 | 1459185941 | 1602970328 | HD1500-7 | 185886000 | 73748250 | 19174545 | 1326610495 | 1268596385 | 1384624605 | 730E 7 | 168480000 | 57651750 | 16142490 | 1251741572 | 1190768159 | 1312714986 | 730E 8 | 170880000 | 58473000 | 19880820 | 1322145992 | 1260262535 | 1384029449 | 830E 1AC | 157140000 | 47796750 | 18162765 | 1267576107 | 1204345468 | 1330806746 | 860E 1K | 215040000 | 42048000 | 17660160 | 1275913567 | 1215843906 | 1335983227 | 930E 4 | 267600000 | 36627750 | 16116210 | 1214489820 | 1162163514 | 1266816126 | 930E 4SE | 267600000 | 36627750 | 17581320 | 1403597995 | 1335760863 | 1471435128 | 960E 1 | 238800000 | 32685750 | 16996590 | 1281234441 | 1220721351 | 1341747531 | 960 2K | 238800000 | 32685750 | 16996590 | 1281234441 | 1220721351 | 1341747531 |

Table 1.5: Haul time cycle analysis for Komatsu 930E-4 Komatsu 930E-4 | Year | 1 | 2 | 3 | 4 | 5 | Seconds: | | | | | | Loading Time 1 | 20 | 20 | 20 | 20 | 20 | Loading Time 2-4 | 90 | 90 | 90 | 90 | 90 | Haul to dump | 36 | 36 | 36 | 36 | 36 | | 30 | 90 | 180 | 240 | 300 | | 54 | 54 | 54 | 54 | 54 | Unload | 40 | 41 | 42 | 43 | 44 | Haul to load | 54 | 54 | 54 | 54 | 54 | | 22.5 | 67.5 | 135 | 180 | 225 | | 36 | 36 | 36 | 36 | 36 | Position Time | 30 | 30 | 30 | 30 | 30 | Total Seconds | 412.5 | 518.5 | 677 | 783 | 889 | Mins | 6.875 | 8.641666667 | 11.28333333 | 13.05 | 14.81666667 | Tonnes Per Cycle | 292 | 292 | 292 | 292 | 292 | Tonnes Per Hour | 2546.618182 | 2025.998071 | 1551.669129 | 1341.609195 | 1181.642295 | Hours Per Shift | 12 | 12 | 12 | 12 | 12 | Tonnes Per Shift | 30559.41818 | 24311.97686 | 18620.02954 | 16099.31034 | 14179.70754 | Shifts Per Year | 365 | 365 | 365 | 365 | 365 | Availability | 85% | 85% | 85% | 85% | 85% | Utilisation Of Availability | 88% | 88% | 88% | 88% | 88% | Operator Efficiency | 87% | 87% | 87% | 87% | 87% | Tonnes Per Year | | Tpa Per Truck | 7258699.146 | 5774760.652 | 4422767.205 | 3824027.328 | 3368069.064 | No Of Trucks For 70Mtpa | 10 | 13 | 16 | 19 | 21 |

Komatsu 930E-4 | 6 | 7 | 8 | 9 | 10 | | | | | | 20 | 20 | 20 | 20 | 20 | 90 | 90 | 90 | 90 | 90 | 36 | 36 | 36 | 36 | 36 | 360 | 420 | 480 | 540 | 600 | 54 | 54 | 54 | 54 | 54 | 45 | 46 | 47 | 48 | 49 | 54 | 54 | 54 | 54 | 54 | 270 | 315 | 360 | 405 | 450 | 36 | 36 | 36 | 36 | 36 | 30 | 30 | 30 | 30 | 30 | 995 | 1101 | 1207 | 1313 | 1419 | 16.58333333 | 18.35 | 20.11666667 | 21.88333333 | 23.65 | 292 | 292 | 292 | 292 | 292 | 1055.758794 | 954.1144414 | 870.3231152 | 800.0609292 | 740.2959831 | 12 | 12 | 12 | 12 | 12 | 12669.10553 | 11449.3733 | 10443.87738 | 9600.73115 | 8883.551797 | 365 | 365 | 365 | 365 | 365 | 85% | 85% | 85% | 85% | 85% | 88% | 88% | 88% | 88% | 88% | 87% | 87% | 87% | 87% | 87% | | | | | | 3009259.696 | 2719539.871 | 2480707.04 | 2280436.708 | 2110086.961 | 24 | 26 | 29 | 31 | 34 |

Table 1.6: Number of loader buckets needed for each truck LOADERS - NUMBER OF BUCKETS NEEDED FOR EACH TRUCK | Model | HD325-7 | HD405-7 | HD465-7E0 | HD785-7 | HD1500-7 | 730E 7 | 730E 8 | EX1200-5D | 3.120 | 5.385 | 4.701 | 7.778 | 12.316 | 15.703 | 15.504 | EX1200-6 | 3.120 | 5.385 | 4.701 | 7.778 | 12.316 | 15.703 | 15.504 | EX1900-6 | 1.690 | 2.917 | 2.546 | 4.213 | 6.671 | 8.506 | 8.398 | EX2500-6 | 1.352 | 2.333 | 2.037 | 3.370 | 5.337 | 6.805 | 6.719 | EX2600-6 | 1.352 | 2.333 | 2.037 | 3.370 | 5.337 | 6.805 | 6.719 | EX3600-6 | 0.966 | 1.667 | 1.455 | 2.407 | 3.812 | 4.861 | 4.799 | EX5500-6 | 0.843 | 1.455 | 1.270 | 2.102 | 3.328 | 4.243 | 4.189 | EX5600-6 | 0.787 | 1.358 | 1.185 | 1.961 | 3.106 | 3.960 | 3.909 | EX8000-6 | 0.570 | 0.984 | 0.859 | 1.422 | 2.252 | 2.871 | 2.834 | Model | 830E 1AC | 860E 1K | 930E 4 | 930E 4SE | 960E 1 | 960 2K | 830E 1AC | EX1200-5D | 18.940 | 21.650 | 24.940 | 24.821 | 27.913 | 27.913 | 18.940 | EX1200-6 | 18.940 | 21.650 | 24.940 | 24.821 | 27.913 | 27.913 | 18.940 | EX1900-6 | 10.259 | 11.727 | 13.509 | 13.444 | 15.119 | 15.119 | 10.259 | EX2500-6 | 8.207 | 9.381 | 10.807 | 10.756 | 12.096 | 12.096 | 8.207 | EX2600-6 | 8.207 | 9.381 | 10.807 | 10.756 | 12.096 | 12.096 | 8.207 | EX3600-6 | 5.862 | 6.701 | 7.720 | 7.683 | 8.640 | 8.640 | 5.862 | EX5500-6 | 5.118 | 5.850 | 6.739 | 6.707 | 7.542 | 7.542 | 5.118 | EX5600-6 | 4.776 | 5.459 | 6.289 | 6.259 | 7.038 | 7.038 | 4.776 | EX8000-6 | 3.463 | 3.958 | 4.559 | 4.538 | 5.103 | 5.103 | 3.463 |

Table 1.7: Haul time cycle analysis for Komatsu 930E-4 considering Hitachi EX8000-6 loader Komatsu 930E-4 | Year | 1 | 2 | 3 | 4 | 5 | Seconds: | | | | | | Loading time 1 | 20 | 20 | 20 | 20 | 20 | Loading time 2-5 | 120 | 120 | 120 | 120 | 120 | | 36 | 36 | 36 | 36 | 36 | | 30 | 90 | 180 | 240 | 300 | | 54 | 54 | 54 | 54 | 54 | | 40 | 41 | 42 | 43 | 44 | | 54 | 54 | 54 | 54 | 54 | | 22.5 | 67.5 | 135 | 180 | 225 | | 36 | 36 | 36 | 36 | 36 | | 30 | 30 | 30 | 30 | 30 | TOTAL Seconds | 442.5 | 548.5 | 707 | 813 | 919 | mins | 7.38 | 9.14 | 11.78 | 13.55 | 15.32 | tonnes per cycle | 292 | 292 | 292 | 292 | 292 | tonnes per hour | 2373.97 | 1915.19 | 1485.83 | 1292.10 | 1143.07 | hours per shift | 12 | 12 | 12 | 12 | 12 | tonnes per shift | 28487.59 | 22982.24 | 17829.93 | 15505.24 | 13716.82 | shifts per year | 365 | 365 | 365 | 365 | 365 | availability | 85% | 85% | 85% | 85% | 85% | utilisation of availability | 88% | 88% | 88% | 88% | 88% | operator efficiency | 87% | 87% | 87% | 87% | 87% | tonnes per year | | | | | | Tpa per truck | 6766583.95 | 5458912.302 | 4235096.744 | 3682919.309 | 3258121.216 | No of trucks for 70Mtpa | 11 | 13 | 17 | 20 | 22 | | | | | | | Year | 6 | 7 | 8 | 9 | 10 | Seconds: | | | | | | Loading time 1 | 20 | 20 | 20 | 20 | 20 | Loading time 2-5 | 120 | 120 | 120 | 120 | 120 | | 36 | 36 | 36 | 36 | 36 | | 360 | 420 | 480 | 540 | 600 | | 54 | 54 | 54 | 54 | 54 | | 45 | 46 | 47 | 48 | 49 | | 54 | 54 | 54 | 54 | 54 | | 270 | 315 | 360 | 405 | 450 | | 36 | 36 | 36 | 36 | 36 | | 30 | 30 | 30 | 30 | 30 | TOTAL Seconds | 1025 | 1131 | 1237 | 1343 | 1449 | mins | 17.08 | 18.85 | 20.62 | 22.38 | 24.15 | tonnes per cycle | 292 | 292 | 292 | 292 | 292 | tonnes per hour | 1024.86 | 928.81 | 849.22 | 782.19 | 724.97 | hours per shift | 12 | 12 | 12 | 12 | 12 | tonnes per shift | 12298.30 | 11145.68 | 10190.59 | 9386.27 | 8699.63 | shifts per year | 365 | 365 | 365 | 365 | 365 | availability | 85% | 85% | 85% | 85% | 85% | utilisation of availability | 88% | 88% | 88% | 88% | 88% | operator efficiency | 87% | 87% | 87% | 87% | 87% | tonnes per year | | | | | | Tpa per truck | 2921183.803 | 2647403.535 | 2420544.38 | 2229496.201 | 2066399.86 | No of trucks for 70Mtpa | 24 | 27 | 29 | 32 | 34 |

Table 1.8: Expected cost calculation for Hitachi EX8000-6 & Komatsu 930E-4 Hitachi EX8000-6 & Komatsu 930E-4 | Year | 1 | 2 | 3 | 4 | 5 | Expected Cost for loading per year | 15806612 | 4806612 | 4806612 | 4806612 | 4806612 | Expected Cost for loading per tonne | 0.23 | 0.07 | 0.07 | 0.07 | 0.07 | Expected Cost for Hauling per year | 118477492.3 | 74018854.56 | 105101579 | 113413622.4 | 116954984.6 | Expected Cost for Hauling per tonne | 1.69 | 1.06 | 1.50 | 1.62 | 1.67 | | | | | | | Year | 6 | 7 | 8 | 9 | 10 | Expected Cost for loading per year | 4806612 | 4806612 | 4806612 | 4806612 | 4806612 | Expected Cost for loading per tonne | 0.07 | 0.07 | 0.07 | 0.07 | 0.07 | Expected Cost for Hauling per year | 126496346.9 | 146808390.2 | 150349752.5 | 170661795.8 | 174203158.1 | Expected Cost for Hauling per tonne | 1.81 | 2.10 | 2.15 | 2.44 | 2.49 |

Table 1.9: Expected cost calculation for Hitachi EX8000-6 & Komatsu 930E-4 considering 10% thresholds. Hitachi EX8000-6 & Komatsu 930E-4 | Year | 1 | 2 | 3 | 4 | 5 | Expected Cost for loading per year | 33159364 | 9503724 | 9503724 | 9503724 | 9503724 | Expected Cost for loading per tonne | 0.47 | 0.14 | 0.14 | 0.14 | 0.14 | Expected Cost for Hauling per year | 130325241.6 | 81420740.02 | 115611736.9 | 124754984.6 | 128650483.1 | Expected Cost for Hauling per tonne | 1.86 | 1.16 | 1.65 | 1.78 | 1.84 | | | | | | | Year | 6 | 7 | 8 | 9 | 10 | Expected Cost for loading per year | 9503724 | 9503724 | 9503724 | 9503724 | 9503724 | Expected Cost for loading per tonne | 0.14 | 0.14 | 0.14 | 0.14 | 0.14 | Expected Cost for Hauling per year | 139145981.6 | 161489229.3 | 165384727.7 | 187727975.4 | 191623473.9 | Expected Cost for Hauling per tonne | 1.99 | 2.31 | 2.36 | 2.68 | 2.74 |

Figure 2: Expected cost of Hauling with sensitivity of fuel cost

Figure 3: Expected cost of Loading with sensitivity of fuel cost

References

Afrouz, A 1992, Practical Handbook of Rock Mass Classification Systems and Modes of Ground failure, CRC Press Inc., USA.

Durham, R 2014, Productivity – Truck & Haul Roads, lecture notes distributed in Resource Extraction Technologies at The University of Western Australia, Crawley on 28 August 2014.

Hitachi Construction Machinery Co. Ltd 2004, Large Excavators / Loading Shovels. Available from: <http://www.hitachi‐cm.com/au/products/excavator/large/>. [14 September 2014].

Karrech, A 2014, Handling, lecture notes distributed in Resource Extraction Technologies at The University of Western Australia, Crawley on 14 August 2014.

Komatsu Australia n.d, Dump Trucks-Rigid. Available from: <http://www.komatsu.com.au/Equipment/Pages/Dump-Trucks-Rigid.aspx>. [14 September 2014].

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