Komatsu: Transform Mining23 Feb - 25 Feb
Secure your site trial in just a weekend!
This competition has finished.
Come rock with us, join the community
program you join.
resources industry. All are welcome.
Realtime Material Characterisation
Komatsu are looking for technologies that can evaluate the characteristics of ore materials (coal, copper, iron) in real time as they are extracted, without impacting productivity.
Can your system relay information, post-blast, about ore characteristics to the fleet, to allow for optimised planning of material movement?
Proposal of Challenge2: Realtime Material Characterisation
Komatsu: Transform Mining Hackathon
23-25 February, 2018
River City Labs, TCB building, the Precinct, 315 Brunswick St.,
Fortitude Valley, QLD 4000, Australia
Atsunori Kikuchi, Komatsu Ltd.
Mr. Roy Pater, MineWare Pty Ltd.
Mr. Gary Robertson, MineWare Pty Ltd.
Mr. Takuma Nakamura, Komatsu Ltd.
Komatsu are looking for technologies that can evaluate the characteristics of ore materials ( gold, copper, iron) or soft rock sedimentary materials (coal, carbonite shale), in real time as they are extracted, without impacting productivity.
Can your system calculate and relay information about material ore characteristics during the loading process, to allow for optimised planning of material movement?
At the commencement of the mining process, an area to be mined is pre-analysed by a geologist in order to get an approximate understanding of the geological composition, strata, and mineral content. This is completed at a very high level (i.e. data sampling of the regions is done only on 50mx50m or 100m x100m grids meaning significant interpolation is required) to construct a geological model.
During the operations phase of the mining process this area is drilled and then blasted to break up the material and allow excavation machinery to excavate it and load it into haul trucks. The blasting techniques used are significant enough to cause the material to shift and expand from its original position. Therefore, the geological model which was initially created by the geologist is no longer accurate.
The essence of this task is to find a solution that is able to re-evaluate the composition of the material in front of the digging machine before or as the machine is digging it. This information can then be utilised to understand the properties of the material within a loaded truck so that it can be delivered to the correct destination. For example, if the truck is loaded with waste material is might go to a waste dump. A truck loaded with ore bearing material might go to a processing facility or a stock pile.
The diagram below shows how the expected location can be significantly different to the actual.
Outline of Challenge
This challenge focuses on determining in real-time what type of material is being loading into haul trucks by digging units.
As per the difficulties highlighted above, often a loaded truck is not sent to the correct location when material identification is based solely on the location of the material being dug being referenced to a geological model. Sometimes the operator can determine what is being loaded, but many materials cannot be differentiated visually, and machines also often work in wet, dusty, or muddy conditions.
This challenge is to develop a platform which can sense what material is being loaded into the truck and then send that information to the truck management system so that the truck is sent to the right dumping location.
The system will be applied at open pit mines with various types of mineral deposit including sedimentary deposits like coal.
A prototype of the platform and processes of ensure the truck can be sent to the correct locations. The system should be:
" Robust or adaptable to different mineral types
" Provide data with which mine geological plans can be updated with accurate material location information.
" Be able to process information on or close to the operating machines as possible
The prototype system should consider components / functions including
1. Robust material sensing approach at some point through the loading process
2. Sensor suite and hardware platform
3. Capability for receiving and updating material models (resource volumetric, geometric, Geo-tech, Geo-met model)
4. Resource reassessment and revaluation based on the material models and data from sensing systems
5. Visualisation and feedback of output data for operators
6. Facilities for interaction and interfacing with truck management systems
Potential Areas To Consider
The operation involves material being dug from the mine working face, loading that material into a truck, and then transporting the material to either a dump (for waste) a stockpile (for ore), or a crusher (for ore) where it is dumped.
Sensing needs to be done prior to the truck loading process being completed and before leaving the loading unit so that the truck operator can travel to the correct destination for the material
The system may use exploratory drilling information as a guide to pre-determine what is approximately at the digging face. This may assist in sensing.
Requirements (Accuracy and other performance)
" Resolution of data for material analysis does not need to be less than 1 sqm
" If sensing material pre-loading, the system does not require penetrative measurement capability, surface measurement is adequate
" Sensing height from the base of the digger unit is up to 20 metres to account for the material face being mined
" Material ore grade resolution should be a minimum of 3 levels: low mid high
" Measurement must be taken during normal machine operations, i.e. machine cannot stop to take a measurement
" The system can measure before the material is dug out or as it is being dug out.
" The materials to be measured will be post blasting.
" Since the target is open pit mine, the system must deal with varying environmental conditions such as dust and lighting (Note: mines stop operation in extreme weather conditions, so torrential rain or show do not need to be considered)
" System must be of a size that can be fitted to a machine or nearby a machine and processing must be completed within a standard loading time for a dig unit - i.e. approx. 30sec.
" The system cannot impact productivity or execution of the mining process.
Key Criteria of Outcomes
There are variety of performance factors.
" Performance of ability to sense ore characteristics
" Resolution of mapping of the dig face (if measuring at pre-loading)
" Capability to store data and compare against original geological model
" Facilities for Communication system with other systems
Out of Focus
Sensor technologies which apply on the lip of the bucket are out of scope. The technology is currently being looked at.
Prototype which can determine material loaded into a truck, and secondarily, is sending material before loading, create a map showing material characteristics at the dig face. The system should also be able to communicate such information to the truck management system and allow for difference between exploration data and acquired data to be calculated.
Atsunori Kikuchi, Lead mentor, Komatsu
Mr. Roy Pater, MineWare
Mr. Gary Robertson, MineWare
Mr. Takuma Nakamura, Komatsu
Reference Data (to be added more)
Dig and load cycle is approximately 30-50 seconds.
Loading unit can excavate roughly 2m depth at once.
Haul truck may hold up to 360t of material
Load unit will place multiple buckets of material in the truck to fill it