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Shovel–Dumper Matching Calculation in Opencast Mining (With Formula & Example) | Indian Minerology

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Shovel–Dumper Matching Calculation in Opencast Mining

Shovel–Dumper Matching Calculation in Opencast Mining (With Formula & Example) | Indian Minerology

Shovel–dumper matching is one of the most important calculations in surface mining operations. Proper matching ensures maximum production, minimum waiting time, and reduced operating cost.

What is Shovel–Dumper Matching?

Shovel–dumper matching means selecting the correct number of dump trucks for one hydraulic shovel so that neither the shovel nor the dump trucks remain idle.

Why Shovel–Dumper Matching is Important?

  • Maximizes production
  • Reduces idle time
  • Saves fuel cost
  • Improves equipment life
  • Optimizes mining operation

Basic Principle of Matching

The total loading time of all dump trucks should be approximately equal to the total cycle time of one dump truck.

Data Required for Calculation

  • Shovel bucket capacity (m³)
  • Shovel cycle time (seconds)
  • Dump truck capacity (tonnes)
  • Truck cycle time (minutes)
  • Material density (t/m³)

Shovel Loading Time Calculation

Formula:

Number of Passes = Truck Capacity (tonnes) / (Bucket Capacity × Fill Factor × Density)

Shovel Loading Time:

Loading Time = Number of Passes × Shovel Cycle Time

Dump Truck Cycle Time

Dump truck cycle time includes:

  • Loading time
  • Hauling loaded
  • Dumping
  • Returning empty
  • Waiting & spotting

Shovel–Dumper Matching Formula

Number of Dump Trucks Required = Dump Truck Cycle Time / Shovel Loading Time

Example Calculation

Bucket Capacity = 10 m³
Fill Factor = 0.9
Material Density = 1.8 t/m³
Dump Truck Capacity = 100 tonnes
Shovel Cycle Time = 30 seconds
Dump Truck Cycle Time = 10 minutes

Step 1: Calculate Material per Bucket

= 10 × 0.9 × 1.8 = 16.2 tonnes

Step 2: Number of Passes

= 100 / 16.2 ≈ 6.17 ≈ 7 passes

Step 3: Shovel Loading Time

= 7 × 30 = 210 seconds = 3.5 minutes

Step 4: Number of Dump Trucks

= 10 / 3.5 = 2.85 ≈ 3 Dump Trucks

Ideal Matching Condition

  • Shovel should not wait for trucks
  • Dump trucks should not queue unnecessarily
  • Matching ratio should be close to whole number

Factors Affecting Shovel–Dumper Matching

  • Haul road condition
  • Bucket fill factor
  • Operator skill
  • Mechanical availability
  • Weather conditions

Common Matching Ratios

  • 10 m³ shovel → 3–4 dump trucks (100T)
  • 20 m³ shovel → 4–6 dump trucks (170T)
  • 40 m³ shovel → 6–8 dump trucks (240T)

Advantages of Proper Matching

  • Lower cost per tonne
  • Higher equipment utilization
  • Fuel savings
  • Smooth mine operation

Frequently Asked Questions (FAQs)

Q1. What happens if dump trucks are more?

Dump trucks will wait in queue, increasing idle time and fuel wastage.

Q2. What happens if dump trucks are less?

Shovel remains idle, reducing production.

Conclusion

Shovel–dumper matching is a critical part of mine planning. Correct calculation helps in achieving maximum productivity with minimum operating cost.

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