Optimizing Material Flow from ROM Pad to Crusher

In modern mining operations, managing raw material flow from the Run-of-Mine (ROM) pad to the crusher is a complex and critical process. The improved efficiency of this process can positively impact ore recovery, mineral conservation, mineral beneficiation cost, metal recovery percentage, process efficiency and overall cost management. The ROM Loader Software by GroundHog is designed to streamline these operations, offering precise tracking, grade control, blend management, and real-time insights into material handling.

Understanding the ROM Pad

The ROM pad serves as a central storage area for run-off mine ore materials of varying grades - high, medium, and low. These materials are strategically organized and stacked into different blocks within the ROM pad to facilitate efficient blending and required feed grade control.

Key Components:

• Material Grades: High, Medium and Low-grade materials are stored separately.
• Block Arrangement: Materials are categorized into blocks, each representing a specific grade and type of ore material.

Wheel Loader Integration

The ROM Loader Software is specifically designed for wheel loaders, the heavy machinery used to transport materials from the ROM pad to the crusher. This software enables precise tracking and control over the material loading process, ensuring that operations adhere to the planned blend sequences.

Use Case Analysis

Use Case 1: Optimizing the Blend Sequence

Each morning, operators receive a blend plan outlining the specific sequence for material loading. This plan ensures the correct proportions of raw materials are loaded to achieve the desired ore blend. For example, the plan might dictate that one bucket of material should be loaded from Block HG01, followed by two buckets from Block LG03. The sequence is crucial for maintaining feed quality, and the ROM Loader Software ensures operators follow this sequence precisely.

Benefits:

• Accurate Blending: Ensures proper mix of raw materials for optimal ore quality.
• Real-Time Guidance: Operators receive real-time instructions, minimizing errors.

Use Case 2: Ensuring Compliance with the Blend Plan

In scenarios where operators deviate from the blend plan, the ROM Loader Software immediately detects the error and sends an alert, guiding the operator back to the correct sequence. This feature is critical for maintaining consistency in the ore blend and preventing costly mistakes.

Benefits:

• Error Prevention: Alerts operators when deviations occur.
• Quality Control: Maintains consistency in material quality.

Use Case 3: Accurate Payload Tracking

Traditionally, tracking the exact amount of material loaded into the crusher has been challenging. The ROM Loader Software solves this by accurately measuring and logging the payload from each bucket, ensuring precise tracking of material flow into the crusher. The VEI integration allows us to achieve this functionality.?

Benefits:

• Precise Measurement: Tracks exact payloads for better inventory management.
• Improved Efficiency: Reduces material wastage and enhances mineral recovery.

Use Case 4: Stockpile Balance Management

Once material is moved from the stockpile to the crusher, it’s essential to update the stockpile records accurately. The ROM Loader Software automates this process, deducting the material from the stockpile in real-time as it is offloaded, thereby maintaining accurate and up-to-date stockpile balances.

Benefits:

• Automated Tracking: Eliminates manual errors in stockpile management.
• Real-Time Updates: Keeps stockpile data current, aiding in resource planning.

Use Case 5: Tracking Bucket Sequence Accuracy through digital inputs

Operators traditionally rely on paper-based methods to track which block they’ve loaded from and what the next block should be. The ROM Loader Software replaces this with a digital system that automatically tracks the sequence, ensuring that operators follow the blend plan accurately and efficiently.?

Benefits:

• Digital Precision: Replaces manual tracking with automated sequence management.
• Enhanced Workflow: Streamlines the loading process, reducing non-productive time.

Use Case 6: Time Utilization Monitoring

The ROM Loader Software includes a Time Utilization Model (TUM) that tracks various operational metrics such as vehicle breakdowns, changes in the blend plan, and non-productive time like lunch breaks. This comprehensive tracking allows for better management of operation time, leading to improved productivity.?

Benefits:

• Detailed Insights: Tracks time usage to identify and reduce inefficiencies.

Operational Efficiency: Helps optimize operation schedules and machinery usage.

Precise Bucket Positioning and Weight Tracking through? VEI Integration

Precision and Accuracy for Your Machinery Operations

We are excited to announce our partnership with VEI, bringing enhanced functionality and unparalleled accuracy to your machinery operations. By integrating four advanced sensors on every piece of equipment—strategically mounted on the boom, stick, and bucket—we can now measure the angles of motion and the weight with centimetre-level precision. This technology allows us to monitor bucket movements on screen, providing detailed, real-time tracking of wheel loaders and other heavy machinery at an incredibly granular level.

• Precise Bucket Positioning: Accurately track the position of the bucket to ensure precise loading and unloading operations.
• Weight Tracking: Monitor the exact weight being moved to maintain accurate stockpile balances and optimize material handling.

This partnership with VEI empowers you to achieve new levels of operational efficiency and accuracy, ensuring that every movement and every load is perfectly tracked and managed.

Conclusion

GroundHog’ ROM Loader Software represents a significant advancement in mining and mineral beneficiation operations, offering detailed tracking of blend management, quality control, real-time adjustments, and automated processes that enhance efficiency and accuracy. By integrating this software into your operations, you can ensure optimal resource utilization, maintain grade and quality control, and achieve higher productivity with reduced overall operational costs.