Logistics at Amona Iron Ore Plant

8/10/2019 Logistics at Amona Iron Ore Plant

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LogisticsAt

SESA Goa Ltd.Amona Beneficiation Plant

Presented by:-

Ritesh Kumar


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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.


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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


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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


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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.


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Codli Mines

Sanvordem stn.

13km.

Sanvordem jetty Capxem jetty

12km.

14 km.


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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.


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Sonshi Mines

Cudnem Pr. Plant

06 km.

Amona Pr. Plant

Amona jetty

09km.

Jetty stack

Mooring Dolphin

TV / FC

Port Berth No.9

Vessel


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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


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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.


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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


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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


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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


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DateTruck Side

no From To Time In

(A)Securitytime(in

seconds)

(B)W/B


(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


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Weighbridge no.05

DateTruck Side

no From To Time In

(A)Securitytime(in

seconds)

(B)W/B


(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


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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


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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


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DateTruck

Side no From To Time In

Securitytime(inseconds)

W/B


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


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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.


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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


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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


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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


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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


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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


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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


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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.


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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.


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hank you

Logistics at Amona Iron Ore Plant

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