Selection and assessment of mining equipment used in open pit rock mines relies chiefly on estimates of overall exploitation cost. The rational arrangement of mining equipment and systems comprising loading machines, haul trucks and crushing plants should be preceded by a thorough analysis of technical and economic aspects, such as investment outlays and the costs of further exploitation, which largely determine the costs of mining operations and the deposit value. Additionally, the operational parameters of the mining equipment ought to be considered. In this study, a universal set of evaluation criteria has been developed, and an evaluation method has been applied for the selection of surface mining equipment and the processing system to be operated in specific mining conditions, defined by the user. The objective of this study is to develop and apply the new methodology of multi-criteria selection of open pit rock mining equipment based on multiple criteria decision-making (MCDM) procedures, to enable the optimization of loading, handling and crushing processes. The methodology, underpinned by the principles of MCDM, provides the dedicated ranking procedures, including the ELECTRE III. The applied methodology allows the alternative options (variants) to be ranked accordingly. Ultimately, a more universal methodology is developed, applicable in other surface mines where geological and mining conditions are similar. It may prove particularly useful in selection and performance assessment of mining equipment and process line configurations in mining of low-quality rock deposits. Therefore, we undertook to develop universal criteria and applications for the selection and performance assessment of process machines for surface mines, taking into account environmental aspects as well as deposit quality.

Analyses and assessments of hazards occurring in work processes are carried out by teams, in which there is usually one representative of the personnel, as the embodiment of the active participation of employees in the assessment of occupational risks. This is why the article presents research on all employees’ knowledge and awareness about risks in their work environment. The research was carried out in the form of an employee survey in one of the open-pit mines, at workstations dealing with the loading and transporting of excavated material. The survey included a list of 40 hazards divided into four groups: (1) hazards related to machines and equipment used, (2) hazards related to exposure, (3) hazards with an impact extending beyond the workstation and (4) hazards of an ergonomic nuisance nature, where employees were required to indicate which hazards apply to their workplaces and determine their level of significance, probability of occurrence and the scale of possible effects. In this way, a hierarchical identification of threats occurring at the analyzed workplaces was made, and the obtained results were used to determine the amount of occupational risk both for specific workstations and for the whole technological process. The measures of the magnitude of occupational risk obtained using the proposed method have showed that, according to the respondents, greatest risks at the workstation are associated with moving machines and vehicles and with mobile equipment. Equally important risks, which were often mentioned by employees, were those directly related to their health, i.e., related to ergonomic nuisance and exposure. Threats resulting from geological and mining conditions, considered typical for mining, were important for the surveyed miners but they were not the most important owing to proper prevention, good organization of work and high safety culture The active involvement of the crew in the process of assessing occupational hazards allowed to identify the significance of each hazard, in the opinion of the personnel working at various places and to use this ranking for determining occupational risk levels in the mining company concerned. The research has also outlined another goal to be achieved: a comparison of the relative significance of hazards identified by the employees and of the hazards listed in occupational risk assessment matrices used by mines.

The article presents an analysis of the influence of selected operating environment parameters on the operation of a technological system in a mine and examines the profitability of exploiting a deposit of low quality. A model based on a cyclical transportation system in a surface limestone mine, developed in the Haulsim software, served to evaluate—from an economic perspective—several material transportation scenarios depending on the quality of the deposit. A discrete simulation of machine operation allowed a detailed analysis of the technological, operating and economic parameters for selected solutions. The results may be the basis for a decision to begin or to resign from mineral extraction. The simulation results demonstrate that maintaining the operating environment in good technical condition positively influences machine operating cycle times, the required total time of the transportation task and the operating costs. The analysis was performed for the production period of one full year, allowing for the effective work and technological downtimes. This approach allowed the usefulness of the model to be demonstrated in evaluating not only the effectiveness of individual technological procedures but also its economic aspect, related to a decision on the exploitation of “difficult” deposits.

This paper presents an analysis of the impact of selected parameters of the operating environment on the energy consumption and reliability of haulage in surface mining. The analysis is based on a cyclic haulage system in a limestone open pit. The results of the calculations show that maintaining the operating environment in good technical condition has a positive effect on the haulage process and a direct or indirect effect on the operating costs, the analysis of which is also presented in the main body of the article. The analysis was carried out for a full year’s production, taking into account actual operating and maintenance downtime. The results of similar analyses can be used as a basis for deciding on the type of truck to be used for transport or for reconfiguring transport routes. In addition to the economic and operational aspects of energy consumption and reliability, the environmental aspect cannot be overlooked. The comparison of two variants of mining conditions shows that a modification of the haul road surface leads to a significant reduction in fuel consumption. Depending on the type of vehicle, fuel consumption can be reduced by almost 20%. The potential reduction in fuel consumption directly translates into lower exhaust emissions, which is an important element of an environmentally sustainable approach to mining transport, and greater reliability increases efficiency and reduces the carbon footprint of the vehicle.

A methodology is outlined for equipment selection for the extraction of secondary deposits, supported by the Multiple Criteria Decision Making (MCDM) tool based on the Analytic Hierarchy Process (AHP) method and applied to evaluate its impact on the mining system’s performance and the viability of the rock mining project. The equipment selection analysis affords us the means to explore selected options, taking technological and economic parameters into account, and opening the way for making the decision to begin or discontinue mining operations. The simulation results show how maintaining the mining site in a good condition impacts on the actual duty cycle of mining equipment, the time required to complete the hauling task and the operating costs.

Vehicle transport is a dominant type of technological processes in rock mines, and its profitability is strictly dependent on overall cost of exploitation. Rational design of mining transportation system based on haul trucks should result from thorough analysis of technical and economic issues, including both cost of purchase and its further exploitation, having a crucial impact on the cost of minerals extraction. Moreover, haul trucks should be selected with type of payload. In this paper a development of universal family of evaluation criteria as well as application of evaluation method for haul truck and processing system selection process for a specific exploitation conditions in surface mining have been carried out. This methodology presented in the paper is based on the principles of multicriteria optimization using one of method, i.e. APEKS. The result of the research is a universal methodology, and it consequently may be applied in other surface mines with similar exploitation parameters.