logistics at amona iron ore plant
TRANSCRIPT
-
8/10/2019 Logistics at Amona Iron Ore Plant
1/28
LogisticsAt
SESA Goa Ltd.Amona Beneficiation Plant
Presented by:-
Ritesh Kumar
-
8/10/2019 Logistics at Amona Iron Ore Plant
2/28
About Sesa Goa ltd.
Sesa Goa is India's largest producer and exporter of Iron Ore inthe private sector, with mining and processing facilities locatedin Goa, Karnataka and Orissa, India.
They are on course to be one of the top four Iron Ore producingcompanies in the world.There Goa operation consist of two major iron ore mining areas
one in Codli village in South Goa district
One in Sonshi village in North Goa districtApart from this their iron ore production is derived from VSDempo mines and other satellite mines in south and north Goadistricts.
-
8/10/2019 Logistics at Amona Iron Ore Plant
3/28
Codli MinesTinaighat/ Karnataka
Codli Pr. Plants
Dharbandora
Usgoan
Capxem Jetty
Sanvordem Jetty
Satellite minesSonshi mines
Surla Jetty
Amona Jetty
Cudnem Pr. Plant
South Goa mines
Transit store Yard
Transit store Yard
Amona Pr. Plant
North Goa Mines
GOA Logistics (Sesa)
Mooring Dolphin
TV / FC
Port Berth No.9
Vessel
Suktalim/RR Plot
Transit store Yard
Tixem JettyKothambi Jetty
-
8/10/2019 Logistics at Amona Iron Ore Plant
4/28
Sesa Goa operates through
Mormugao Port in Goa
Mangalore in Karnataka
Karwar in Karnataka
Belekeri in Karnataka
Kolkata in West Bengal
Haldia in West Bengal
Paradip in Orissa
Krishnapatnam in Andhra Pradesh
Vizag in Andhra Pradesh
-
8/10/2019 Logistics at Amona Iron Ore Plant
5/28
Codli minesCodli mine first commenced production in 1973.
Codli is situated in South Goa, approximately 50 kilometres east of Panaji.Codli mines are open-pit operation, multi-pit, multi-lease fully mechanisedmining units.The nearest railway stations, Sanvordem and Margao, are approximately 13kilometres and 40 kilometres, respectively, from the mine.
The river loading points at Sanvordem and Capxem are approximately 12kilometres and 14 kilometres, respectively.From the Codli mines the port is approximately 40 nautical miles.They have extensive ore processing facilities for upgrading the ore, whichinclude crushing, dry screening, scrubbing, log washing, classifying,
hydrocycloning, and magnetic separation with ultra fines recovery.codli has 4 processing plants one for processing high grade ore and rest allfor low grade ore.
-
8/10/2019 Logistics at Amona Iron Ore Plant
6/28
Codli Mines
Sanvordem stn.
13km.
Sanvordem jetty Capxem jetty
12km.
14 km.
-
8/10/2019 Logistics at Amona Iron Ore Plant
7/28
Sonshi minesMining at Sonshi commenced in 1958.Sonshi is one of the oldest operating mine by Sesa Goa.It is situated in North Goa, approximately 34 kilometres from Panaji.Sonshi mine comprises of an open-pit mine and it is fully mechanised mining unit.Over 2.0 million tonnes of iron ore was produced from Sonshi in FY2010.Current production capacity is more than 3.0 mtpa.
Near Sonshi Mine they also operate Mareto Sodo Mine with a production capacity of 0.5mtpa.The nearest railway station, Thivim is approximately 25 kilometres, from the mine.The river loading point Amona is 9 Kilometres from the mine.The port is approximately 35 nautical miles from the river loading point.At Sonshi they don't have any processing plant onsite.
The extracted ore is transported by road to the processing plants at Amona approximatelynine kilometres away and at Cudnem approximately six kilometres away.The processed and unprocessed ore is transported by road to a riverhead jetty by 10 tonnetipper trucks at Amona Jetty and then further transported by barges to the Goa port ortranshipper for onward shipment.
-
8/10/2019 Logistics at Amona Iron Ore Plant
8/28
Sonshi Mines
Cudnem Pr. Plant
06 km.
Amona Pr. Plant
Amona jetty
09km.
Jetty stack
Mooring Dolphin
TV / FC
Port Berth No.9
Vessel
-
8/10/2019 Logistics at Amona Iron Ore Plant
9/28
North Goa Mines South Goa Mines Transit Points
Sonshi Codli Usgaon
Sanquelim RR plot
Mareta sodo Dharbandora
Botvadecho Dongor
Orasso Dongor
Surla (VS Dempo)
Bicholim(VS Dempo)
Sesa Goa Mines
-
8/10/2019 Logistics at Amona Iron Ore Plant
10/28
Amona Processing Plant Amona Plant is a strategically situated processing plant in North Goa at the banks of
river Mandovi. It is approximately 09 km from Sonshi mines and approximately 40-50 km from Codli
mines.It has facility of barge loading also where the iron ore is finally loaded for
transshipment or transported to the port for final loading at designated vessel.
It has compliment of two processing plants currently operating namely- plant 1-Aand plant 1-C. one more upcoming plant 1-B is under construction which will becommencing its operation soon.
It has compliment of around 9-10 mobile iron ore processing plants which can bemobilize to any point.
It comprises of 7 functional weighbridges and two upcoming weighbridges almostready for commencement for operations.
-
8/10/2019 Logistics at Amona Iron Ore Plant
11/28
Process map of iron ore transportation
Mines sonshi,codli, OD
Dumper 40-50 tonnes
Mine stack 600-700 TPH
Wheel Loader
10-30 tons
Tippers
Dry ScreeningWet ProcessingTailing disposal
Beneficiation Plant
Stock PilingDrying
Plant Stacks10 tonsTippers
Weigh-Bridge
750-2500 TonsOwn/TC/ Spot hired
Barges
500-1600 TPH
Transhipper
55000-60000
Bulk carrier
-
8/10/2019 Logistics at Amona Iron Ore Plant
12/28
Time study of weighbridgesweighbridge no.02
DateTruck
Side no From To Time In
(A)Securitytime(in
seconds)
(B)W/B
processingtime(inmm:ss)
(C)Securitytime(in
seconds)
(D)W/B OUTtime(inmm:ss) Time Out
(A+B+C+D)
TotalTime(inmm:ss)
01-02-2011
PVG-
3093 USGAON AMONA 14:33 00:20 00:49 00:09 00:09 14:34 01:27
01-02-2011PVG-4559 USGAON AMONA 14:36 00:24 00:53 00:15 00:15 14:37 01:37
01-02-2011PVG-5032 USGAON AMONA 14:38 00:18 00:49 00:23 00:17 14:39 01:47
01-02-2011PVG-6347 DHARBANDORA AMONA 14:39 00:17 01:05 00:16 00:17 14:41 01:55
01-02-2011PVG-4911 USGAON AMONA 14:41 00:19 00:47 00:17 00:12 14:42 01:35
AVERAGE 00:19 00:52 00:16 00:14 01:40
-
8/10/2019 Logistics at Amona Iron Ore Plant
13/28
weighbridge no.03
DateTruck Side
no From To Time In
(A)Securitytime(in
seconds)
(B)W/B
processing time(inmm:ss)
(C)Securitytime(in
seconds)
(D)W/B OUTtime(inmm:ss) Time Out
(A+B+C+D)
TotalTime(inmm:ss)
01-02-
2011 PVG-4005 DHARBANDORA AMONA 10:57 00:16 00:45 00:15 00:15 10:58 01:31
01-02-2011 PVG-5145 USGAON AMONA 14:28 00:17 00:56 00:08 00:08 14:29 01:29
01-02-2011 PVG-3647 CODLI AMONA 14:52 00:25 01:15 00:15 00:15 14:54 02:10
01-02-2011 PVG-4363 USGAON AMONA 14:56 00:15 01:00 00:13 00:14 14:57 01:42
01-02-2011 PVG-5570 USGAON AMONA 15:09 00:14 00:56 00:17 00:13 15:10 01:40
AVERAGE 00:17 00:58 00:13 00:13 01:42
-
8/10/2019 Logistics at Amona Iron Ore Plant
14/28
DateTruck Side
no From To Time In
(A)Securitytime(in
seconds)
(B)W/B
processingtime(inmm:ss)
(C)Securitytime(in
seconds)
(D)W/B OUTtime(inmm:ss)
TimeOut
(A+B+C+D)
TotalTime(inmm:ss)
07-02-2011 PVG-4132 USGAON AMONA 10:37 00:14 00:53 00:12 00:11 10:38 01:30
07-02-2011 PVG-3473 RRPLOT AMONA 10:38 00:13 00:52 00:13 00:20 10:40 01:38
07-02-2011 PVG-2394 USGAON AMONA 10:40 00:17 00:47 00:11 00:10 10:41 01:25
07-02-2011 AMIT-144 SONSHI AMONA 10:41 00:16 01:30 00:10 00:10 10:43 02:06
07-02-2011 PVG-5768 USGAON AMONA 10:43 00:19 01:19 00:15 00:11 10:45 02:04
AVERAGE 00:15 01:04 00:12 00:12 01:44
Weighbridge no. 04
-
8/10/2019 Logistics at Amona Iron Ore Plant
15/28
Weighbridge no.05
DateTruck Side
no From To Time In
(A)Securitytime(in
seconds)
(B)W/B
processingtime(inmm:ss)
(C)Securitytime(in
seconds)
(D)W/B OUT
time(inmm:ss)
TimeOut
(A+B+C+D)
TotalTime(inmm:ss)
07-02-2011 PVG-5012 USGAON AMONA 10:12 00:20 00:45 00:15 00:18 10:13 01:38
07-02-2011 PVG-4445 USGAON AMONA 10:14 00:23 00:47 00:12 00:13 10:15 01:25
07-02-2011 PVG-5054 USGAON AMONA 10:15 00:18 00:49 00:10 00:18 10:17 01:35
07-02-2011 PVG-5853 USGAON AMONA 10:19 00:34 01:00 00:18 00:13 10:22 02:05
AVERAGE 00:23 00:50 00:13 00:15 01:40
-
8/10/2019 Logistics at Amona Iron Ore Plant
16/28
Average of average timesWeighbridge no.AverageSecurity
time(inseconds)
AverageW/B
processing
time(inmm:ss)
AverageSecurity
time(inseconds)
AverageW/B OUT
time(inmm:ss)
AverageTotalTime
W/b 02 00:19 00:52 00:16 00:14 01:40W/b 03 00:17 00:58 00:13 00:13 01:42W/b 04 00:15 01:04 00:12 00:12 01:44
W/b 05 00:23 00:50 00:13 00:15 01:40
Average time 00:18 00:56 00:13 00:13 01:41
-
8/10/2019 Logistics at Amona Iron Ore Plant
17/28
Chart showing average time taken in each activity at weighbridge
Time(in ss) 10 20 30 40 50 60 70 80 90 100 110 120 130 140
Security 18 sec
Security processing 13 sec
Weighbridge out 13 sec
Overall average time taken in weighbridge activities is 01:40 sec
Weighbridge processing 56 sec
-
8/10/2019 Logistics at Amona Iron Ore Plant
18/28
DateTruck
Side no From To Time In
Securitytime(inseconds)
W/B
processingtime(inmm:ss)
Securitytime(inseconds)
W/B OUTtime(inmm:ss)
TimeOut
TotalTime(inmm:ss)
28-03-2011 PVG5900 RRPLOT AMONA 10:25 00:10 00:15 00:10 00:09 10:25 00:44
28-03-2011 PVG4332 USGAON AMONA 10:28 00:13 00:18 00:12 00:10 10:29 00:53
28-03-2011 PVG4307 DHARBANDORA AMONA 11:06 00:11 00:14 00:10 00:10 11:07 00:47
28-03-2011 PVG6838 RRPLOT AMONA 11:36 00:10 00:12 00:12 00:09 11:37 00:31
28-03-2011 PVG3827 DHARBANDORA AMONA 11:54 00:11 00:16 00:11 00:10 11:55 00:48
AVERAGE 00:11 00:15 00:11 00:09 00:44
Time study of weighbridgesweighbridge no.03 On 28-03-2011
-
8/10/2019 Logistics at Amona Iron Ore Plant
19/28
Total time taken by a truck inside Amona plant
DATE AND TIME SIDE NO.
(A)QUE
TIME(MM:SS)
(B)W/B
PROCESSINGTIME
(C)TIME TOREACHSTACK
(D)UNLOADING
TIME
(E)TIME TOREACH
OUTGATE
(A+B+C+D+E)OVERALL
TIME
07-02-2011 14:33PVG-2787 05:14 02:21 03:04 02:45 04:32 17:57
07-02-2011 14:52
PVG-5797 03:06 01:36 03:18 01:17 04:12 13:3007-02-2011 15:13
PVG-5813 06:48 02:03 01:18 04:35 03:30 18:14
08-02-2011 10:28PVG-5133 02:17 01:32 04:06 03:12 03:43 14:50
09-02-2011 10:14
PVG-6220 00:37 02:17 03:16 05:13 04:46 17:55
Average time 03:36 01:57 03:00 03:24 04:08 16:29
Note: due to safety and security reasons further study was stopped as security personneldidnt allowed to go with trucks inside the plant.
-
8/10/2019 Logistics at Amona Iron Ore Plant
20/28
Chart showing average time taken by trucks inside Amona
Time(in min) 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
03:36
Approach to w/b
01:57
w/b processing
03:00
03:24
Time to reach stack
Unloading at stack
04:08 Time to reach out gate
Overall time taken to complete one trip is 16:29 sec
-
8/10/2019 Logistics at Amona Iron Ore Plant
21/28
No of trips
No. of trucks
1 72
2 29
3 21
4 26
5 23
6 16
7 8
8 7
9 2 10 3
11 3
12 3
13
1
Trip details from RRPLOT to Amona from 12 feb 2011 to 28 mar 2011
-
8/10/2019 Logistics at Amona Iron Ore Plant
22/28
0
10
20
30
40
50
60
70
80
1 2 3 4 5 6 7 8 9 10 11 12 13
N o
. o
f t r u c k s
Trips
Trip details from RRPLOT to Amona from 12-02-2011 to 28-03-
2011
-
8/10/2019 Logistics at Amona Iron Ore Plant
23/28
Truck no. Tonnage carried fromUSTP(net weight in kg.)
Tonnage received atAmona(net weight in kg.) Difference
PVG1448 14160 14190 30PVG1448 13480 13410 -70PVG1448 15970 15950 -20PVG1448 11640 11600 -40PVG1448 15190 15200 10PVG1448 14040 14060 20PVG1448 12280 12350 70PVG1448 13010 13050 40PVG1448 13580 13520 -60PVG1448 12330 12230 -100PVG1448 15350 15400 50PVG1448 14570 14580 10PVG1448 14950 14960 10PVG1448 14900 14920 20PVG1448 12370 12420 50PVG1448 14990 14990 0
Total tonnage 222810 222830
Tripwise tonnage details from 06-03-2011 to 12-03-2011 fromUsgaon to Amona
-
8/10/2019 Logistics at Amona Iron Ore Plant
24/28
Total tonnage(IN TONNES) Date RRPLOT USTP DHARBANDORA
07/03/2011 2560.84 5898.14 2259.68
08/03/2011 2153.55 6750.13 2375.03
09/03/2011 2192.88 7111.27 2526.65
10/03/2011 1126.77 8811.41 1688.97
11/03/2011 1964.57 6326.73 1959.36
12/03/2011 1725.30 4976.07 1451.55
Average tonnage1953.99 6645.63 2043.54
Locationwise tonnage report
-
8/10/2019 Logistics at Amona Iron Ore Plant
25/28
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000
8,000,000
9,000,00010,000,000
RRPLOT
USTP
DHTP
Date
Tonnage
Locationwise tonnage from 06-03-2011 to 12-03-2011
-
8/10/2019 Logistics at Amona Iron Ore Plant
26/28
ObservationsThe traffic system inside plant is very vulnerable as trucks come at high speed and try to overtake each other which sometimes results in accident. Speed breakers should be constructed toreduce truck speed and avoid any accidents and speed restrictions should be imposed like it isprevailing in Sonshi. There is no proper maintenance of the weighbridges and there condition check is not donefrom last few months.The load cells of the weighbridge number 2 needs to be replaced as it has analog cell and
others have digital load cell. This also leads to difference in the weight of the trucks tonnage.There is overloading of the ore on the trucks which results in reduction of the truck speedand in turn their turn around time is increased and they feel difficulty in unloading.Installation of new tarpaulin shed has increased the number of incoming trucks and reducedthe traffic blocks which was there at old tarpaulin untying shed.Under the guidance of the logistics in-charge the weighbridge operators are learning quickly
and adapting to new software such as SAP and RFID.After time study of weighbridges the down time of the weighbridges has been reducedinstead of going in two shifts for lunch now they are going in three shifts.Proper eating facility should be provided to security personnels for their lunch etc.There should be provision of proper sanitary facility as operators have to go down to office foremergency which results in the loss the productive time.
-
8/10/2019 Logistics at Amona Iron Ore Plant
27/28
Electrical fittings should be inspected at regular interval of time by the electricians to ensureits safe working.
Drinking water facility should be provided for security personnel so that their time to go to thegate to bring water is reduced and they concentrate more on the work.The OTS software which is used to save the data requires some changes which has been aproblem for most of the wrong entries. The save option in the software should be moved toextreme right side as when operator tries to shift from destination point window to loadingpoint window sometimes due to system problem the save button is clicked and the wrong
truck data is entered.The efficiency of the weighbridge operator depends upon the type of hardware they areworking. The keyboards are required to be replaced by soft key keyboards which helps them infast typing and data entry.
-
8/10/2019 Logistics at Amona Iron Ore Plant
28/28
hank you